Some basic 300 TDI questions, I hope

I have a disco 1 300 TDI in my 1985 One Ten. It was a conversion from a V8 done by the previous owner a while back.

Been slowly over hauling everything as I'm currently out in the middle east and driving back to the uk via china in about a year (around 50,000km). So need to know how she goes together, and I'm learning a lot!

So far so good, track rod ends, ball joints, fluids, bulbs, etc. But now onto things that I can get very wrong without some advice.

1. Air Con, Essential out here - The clutch wire from the compressor goes no where! Does this mean the clutch is always engaged or has never been engaged?
2. The air con unit is a bit of a mash up of various systems, and I have the fans mounted below the rear passenger's door. They are protected from knocks, but is this a good idea in the long run? Does this mean the engine will run too cold by the time we get North?
3. One of the glow plugs in not connected, is loose and looks a bit rusty, how can I test it? fix it in tight? Easy to replace?
4. There is a single medium gauge wire coming off the top of the engine which seems to run to earth. does this sound right?
5. There are tones of wiring left over from the v8 set up which I am slowly going through and putting to one side, and replacing. Do I need to stick to the earth points for any reason, or will any piece of metal work on the body/chassis do?

Many thanks for any advice - A landrover garage is a very rare thing indeed out here! As are parts!!!!

Attached photos of the glow plus, wire on the top of the engine, and one more mystery wire that goes from the accelerator lever to NO WHERE! another strange casualty of the V8 to TDI conversion? Is this important?

Answered my own question: The wire from the throttle link is a senor for the Egr valve. Explains why it's dead ended.

That first picture of the glow plug, the rest of the glow plug is still screwed in the engine. You need to replace that one it's f*****, and while you're at it take the others out and test them to make sure they work.

NiallRussell said:

Attached photos of the glow plus, wire on the top of the engine, and one more mystery wire that goes from the accelerator lever to NO WHERE! another strange casualty of the V8 to TDI conversion? Is this important?

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Assuming the middle picture is showing the top of the head, the item in question is a water temp sensor.

thebiglad said:

Assuming the middle picture is showing the top of the head, the item in question is a water temp sensor.

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I think thats for the EGR valve, so don't really need it. The temperature gauge sender is at the front in the thermostat housing.

Yes the photo is the top of the head - I'm lifting the engine cover to take the photo.

It isn't connected to anything and the engine is running fine. I have water temp sensor giving me numbers which seems to be working with no problems.

Ian46 said:

That first picture of the glow plug, the rest of the glow plug is still screwed in the engine. You need to replace that one it's f*****, and while you're at it take the others out and test them to make sure they work.

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Nice to know it's f***** as that makes for a clear decision on repair. I will order some from the UK and try and remove the rest of the it still in the engine. I take it this is just the filament from the inside of the glow plug?

Any chance this has done some damage to the inside of the engine in anyway? Should i follow it up with any inspections?

NiallRussell said:

Nice to know it's f***** as that makes for a clear decision on repair. I will order some from the UK and try and remove the rest of the it still in the engine. I take it this is just the filament from the inside of the glow plug?

Any chance this has done some damage to the inside of the engine in anyway? Should i follow it up with any inspections?

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Once you've got the shroud out, it'll be perfectly fine.

As they're so cheap in the UK I would replace all 4.


Dave

NiallRussell said:

Yes the photo is the top of the head - I'm lifting the engine cover to take the photo.

It isn't connected to anything and the engine is running fine. I have water temp sensor giving me numbers which seems to be working with no problems.

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The top of the head coolant temp sensor is used on EDC cars to adjust timing and the operation of the EGR.


Dave

thebiglad said:

The top of the head coolant temp sensor is used on EDC cars to adjust timing and the operation of the EGR.


Dave

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ok so there should be a bunch of stuff that is connected for a EDC setup but isn't being used here. I will try and get a list of what else there is from somewhere and i can go tidy those wires up as well!!

You haven't got an EDC pump, your pump is the old conventional pump with an accelerator cable attached. You can see it in the third photo!

Ian46 said:

You haven't got an EDC pump, your pump is the old conventional pump with an accelerator cable attached. You can see it in the third photo!

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Cracking!!

I'm good a removing un-needed stuff, not great at repair work.