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  #1  
Old April 28th, 2010, 04:54 PM
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Options for re-wiring a 200tdi

Hello,
My 84 suffered an electrical fire within one mile of my home on its maiden voyage. It looks as though the engine loom (harness) is toast. I'm not very confident about what I'd find remaining of the wires going into the dash either.

If I decide to replace the entire vehicle's harness is a place like Auto Sparks my best bet?

http://www.autosparks.co.uk/index.php?cPath=114

It would seem with all the interchangeability between the NA and turbo diesel motors that there should be a bunch of looms on the used market but would I be better off just buying new and starting from scratch? Or the third option would be a custom loom I guess... Any thoughts?

I have no radio or AC so I'm hoping it's a fairly simple endeavor.
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  #2  
Old April 28th, 2010, 05:01 PM
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I've bought from autosparks, and am quite pleased.
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  #3  
Old April 28th, 2010, 06:14 PM
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They seem to have a good reputation alright. Do you know how many looms are involved total? There is the engine, and what I've seen described as the "main" or "body" loom... am I missing anything?
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  #4  
Old April 28th, 2010, 06:45 PM
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Alastair,

George @ RDS has the proper wire harness for the motor.
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  #5  
Old April 28th, 2010, 07:23 PM
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Find out what melted and why before you buy anything.
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  #6  
Old April 28th, 2010, 09:03 PM
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Dave, I saw the engine loom on the RDS site, thanks.

As for the cause of the flare up: My limited arson training leads me to believe that an exposed wire grounded out on a fuel line at the top of the engine bay. The melting seems to originate there. I'll try to upload a picture from my phone...

I think (hope) that replacing all the wiring, and reenforcing the rotted battery bay, will prevent future smokey incidents.
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  #7  
Old April 28th, 2010, 10:06 PM
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The engine "loom" is only a few wires. It is easy enough to repair. While you are at it, you can put in a properly sized alternator wire.
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  #8  
Old April 28th, 2010, 10:34 PM
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Quote:
Originally Posted by Red90 View Post
The engine "loom" is only a few wires. It is easy enough to repair. While you are at it, you can put in a properly sized alternator wire.
Is the alt' wire flimsy? Are there other worthwhile upgrades while I'm under there? My truck arrived with a positive ground, which makes me a bit nervous.
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  #9  
Old April 28th, 2010, 11:27 PM
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I think there are two versions. Mine used two 12 gauge wires for the alternator power and another 2 for supplying power back to the main loom. Not exactly overkill.

The "loom" has, IIRC.

- Two main power wires from main loom to starter terminal
- Two power wires from alternator to starter terminal.
- Alternator warning light.
- Coolant temperature.
- Injection pump solenoid.
- Oil pressure switch.
- Starter solenoid power.
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  #10  
Old April 29th, 2010, 12:26 AM
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My advice is based on a 300 TDi but may be relevent. Replace it all yourself. Don't buy anything. It's all fubar on there and if you are good at wiring, you will do a better and more simple job than they did.
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  #11  
Old April 29th, 2010, 11:09 AM
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I think ground-up re-wiring is going to be the ticket... This is the starting point:
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  #12  
Old April 30th, 2010, 11:24 AM
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Does not look that bad to me. Start checking things with a multimeter to see if there is still continuity.
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  #13  
Old April 30th, 2010, 03:52 PM
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Could have been some type of glow plug harness meltdown.. My truck had that happen prior to me rebuilding it..
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  #14  
Old April 30th, 2010, 08:49 PM
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Ron, that's reassuring to hear. I have a lot of faith in the guy that will be helping me.

Manny, I don't believe the glowplugs made the trip from the Discovery... Are they a worthy retrofit?
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  #15  
Old May 1st, 2010, 09:05 AM
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You should only have a few wires in that area. One would be your glow plug wire but it looks like it is lower than the damaged area. Check to make sure that you glow plug timer, relay is hooked up. The other wiring loom should contain the wires for the alternator, water temp sender, oil sender and fuel injector. The solid brown wires should be going to the Alternator. Yellow/black wire for the glow Plug, White/green to the fuel injector, and White/brown to the oil filter housing. Depending upon how they did the engine conversion is whether they converted another harness and adapted it to the 200 Tdi. I would make sure that they used a main fuse for the wires. On one of mine they bypassed the standard fuse relay on the firewall since the original motor didn't have it.
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  #16  
Old May 1st, 2010, 03:07 PM
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It looks like four total wires were burnt through by this incident. The worst of these runs all the way down to the starter and is a mass of exposed, blackened copper. I'm still not sure what (if any) damage exists behind the dash. The truck is still sitting outside my work. I had hoped to get it into the shop this weekend but it doesn't look like that will happen.
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  #17  
Old May 24th, 2010, 11:38 AM
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update

I managed to get my truck onto a trailer and transported the 86 miles to where its resurrection will begin. The damage caused by the fire turned out to be extensive; going all the way back into the dash. In one regard the fact that the fire happened so close to home, and after only 1.5 miles of ownership, is a blessing. It could have been much worse.
Pulling the dash revealed a labyrinth of exposed and obsolete wires going in every direction. The battery itself was precariously loose on what was left of its tray. There were wires to nowhere running inside the length of the roof and the wires to the tail lamps were twisted together. The fact that it arrived with no coolant and without a reverse gear seem like small potatoes when I think about how the inevitable fire COULD have gone. So while Iíll be without the use of the truck while this project continues it beats the alternative of driving a time bomb.
Iíve also used the down-time to take off the roof and have a hoopset standing by for when the big jobs are finished.
I've taken some cell phone pictures of one or two of the things described above. You'll also see the front bumper. This was "secured" to the front of the truck by two pins. I was wondering why it rocked back and forth. I was able to pick it straight up and off the frame with my hands!
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  #18  
Old May 24th, 2010, 04:13 PM
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Quote:
Originally Posted by alastair View Post
Is the alt' wire flimsy? Are there other worthwhile upgrades while I'm under there? My truck arrived with a positive ground, which makes me a bit nervous.
It would make me nervous too, if an 84 came over with a positive ground. I'd go through the electrical system front to back with a fine tooth comb. No telling what else is a SPOT.
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  #19  
Old May 24th, 2010, 04:38 PM
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You sure someone just did not hook up the battery terminals backwards ie that it was not intended to be positive ground?
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  #20  
Old May 24th, 2010, 05:37 PM
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Alastair,

I sold my old harness from my 1984 90" with my 2.5 motor, I do not think the new owner is going to use it.

The harness was in good condition with no issues, I only swapped it becuase I went with a higher output alternator and did not want to modify the stock harness with larger wires.

If you think that is something you would be intrested in let me know and I will send you his email address.

After my build gets started I may also have a chassis harness, everything works just figured since I was fitting a new chassis that a new harness would be the way to go.
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