Burnt out - rebuild

miktdish said:

The bit that gets hot pokes through into the chamber and the body of the plug rests on a 'face'. The body of the glow plug (which forms the seal) is held tight (to the face) by the threaded part which protrudes out of the head.

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So based on the old plug clearly not sealing and sooting up to the point of siezing, and the fact the new one does either means the lower face is probably damaged and not sealing correctly?
Any suggestions for repair before I go for the exhaust cement bodge Britannica did in the video above?

The sooting is what probably what sealed the original plug, could be the hole base was nor flat in the first place. Think I would go for the Britanica fix. Nothing wrong with a good bodge.

Yes, lilely the lower face is damaged ...

There is a difference in the plugs too ... Chinese ones have a poor mating surface whereas the European versions are machined a lot better.
I thought the 'repair tool' dressed the face as well as the threads ?

miktdish said:

Yes, lilely the lower face is damaged ...

There is a difference in the plugs too ... Chinese ones have a poor mating surface whereas the European versions are machined a lot better.
I thought the 'repair tool' dressed the face as well as the threads ?

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These are proper glow plugs (can’t remember the brand but are oem) not cheap Chinese knock offs.
The repair kit I have doesn’t touch the lower face and is entirely a thread repair kit. The only difference is it designed to be able to be used with the head still fitted so has a “plug” to stop swarf dropping into the cylinder. There is also a centring rod up from said plug. Both of which are a complete waste of time which is why I ended up taking the head off.

I have another specific thread here (link) on this issue but am going to ask it here as well.

I have got to the point of installing the new bulkhead wiring loom (300tdi) I have got as far as running it though the bulkhead and am as happy as I can be with the where everything needs to go on the dash side I just have the laborious process of fitting it all in, refitting the dash and then beginning to connect things up.



AS I have a bare bulkhead and and a crispy fire damaged bulkhead I am not so sure of the cable routing and securing measures for the engine side of the bulkhead. I know where the bits of loom should go (i think) but not the correct, or most sensible routing for it to take, and also not sure how it is supposed to be secured in place so it does not wander and chafe.

If anyone has or could take pictures of their engine side bulkhead wiring that would be much appreciated, and any details on what should be used to clip in in place around the bulkhead and down the to wing corners.

Also what is this plug for? Clearly some sort of relay i would guess but do not recognize it from my old loom. again where should it be secures on the bulkhead.

I have also managed to rub down and prime some more body panels, hopefully by the end of the week these will be fully painted and ready to fit, although they will not be fitted until the end. This will leave only the door bottoms left to paint and they have not been ordered yet as I am going to get galv framed replacements as the old ones have already ben repaired once and once again the lower frame has rotted out (despite huge amounts of dinitrol) and the upper frame has cracked. Hopefully this will not be an issue with galv frames moving forward although I will still was the inside as a precaution.

dag019 said:

I have another specific thread here (link) on this issue but am going to ask it here as well.

I have got to the point of installing the new bulkhead wiring loom (300tdi) I have got as far as running it though the bulkhead and am as happy as I can be with the where everything needs to go on the dash side I just have the laborious process of fitting it all in, refitting the dash and then beginning to connect things up.

View attachment 277659 View attachment 277658

AS I have a bare bulkhead and and a crispy fire damaged bulkhead I am not so sure of the cable routing and securing measures for the engine side of the bulkhead. I know where the bits of loom should go (i think) but not the correct, or most sensible routing for it to take, and also not sure how it is supposed to be secured in place so it does not wander and chafe.

If anyone has or could take pictures of their engine side bulkhead wiring that would be much appreciated, and any details on what should be used to clip in in place around the bulkhead and down the to wing corners.

Also what is this plug for? Clearly some sort of relay i would guess but do not recognize it from my old loom. again where should it be secures on the bulkhead.

View attachment 277660

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Does it have a large brown wire?
Could be glow plug relay?

dag019 said:

I have another specific thread here (link) on this issue but am going to ask it here as well.
Also what is this plug for? Clearly some sort of relay i would guess but do not recognize it from my old loom. again where should it be secures on the bulkhead.

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Is that for the heater/glow plug relay ?
Fits on the bulkhead just above and to the right of the cable entry ...

miktdish said:

Is that for the heater/glow plug relay ?
Fits on the bulkhead just above and to the right of the cable entry ...

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Hicap phill said:

Does it have a large brown wire?
Could be glow plug relay?

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Many thanks I will assume it is the glowplug relay as it doe indeed have a large diameter brown wire. Where else would it be fitted as I do not recall having one externally previously?

If fitted on the right does that mean it is somewhere up near the fuel filter?

dag019 said:

Many thanks I will assume it is the glowplug relay as it doe indeed have a large diameter brown wire. Where else would it be fitted as I do not recall having one externally previously?

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You should have a black/yellow cable with a circle crimp for the glow plug.
Attached to bulkhead by engine.
For all other cables use P clips, landrover used re usable cable ties that fix into holes in bulkhead

Tis always on the bulkhead as far as I know ...

Well I have now finally got back around to installing the bulkhead wiring gloom as the one I had was the incorrect one and had the earlier rubber bullet connectors for the steering column switches. I now have the correct loom with the later white plastic spade connectors. Now refitted and have fitted the fuse box ready for the lower dash to be fitted. This means ahead of me I will have a long time of trying to work out where everything should be situated, the correct wiring routing, and where everything plugs in so bear with me for an endless number of electrical questions to come!



I have also been busy trying to ensure it does not catch fire again and have made up new battery cables and fitted the isolator solenoid which will be connected to a switch on the dash exactly the same as the winch isolator on the other side of the battery box. I plan on having a simple fused bypass between the two solenoid terminals on this at the lowest amps I can get away with to ensure the radio, clock etc maintains a permanent power supply but anything more than those items will pop the fuse.



In the mean time I am trying to fit the lower dash does anyone know the size of the bolts in the that hold the top edge n place? The bulkhead I have is filled with paint and zinc plate so need to retap them and order replacement bolts.

Many thanks to @border for inadvertently answering the question about the engine bay wiring routing and helping greatly by trying to sell his friends land rover (link) (which looks very clean and tidy). These pictures have helped enormously in tracking down the correct routing for the wiring loom and how/what it is secured to across the bulkhead.

However does anyone know what this cover is/part number? I have not seen it before on either my old bulkhead or the donor I have. it looks like it protects the wiring loom where it goes through the bulkhead and possibly acts as a heatshield against the back of the engine?

Yes just a cover for the loom, you could fold one from some alloy sheet. Find a second hand one? Recon finding a new one may be a bit hen's teeth.

I've been looking at these after breaking mine t'other day .....

They are part # AMR4741
Around £50

https://www.lrworkshop.com/parts/AMR4741
https://www.lrparts.net/amr4741-cover-wiring.html
Mr Blanchard has some (used) @ £20 ... I am going to repair mine

I am in the process of fitting an autosparks LR606 300tdi main bulkhead loom to my rebuild and am now trying to match connectors and wiring colours to the things they should connect to. Below are the ones so far I have not managed to identify on the engine bay side of things or want some reassurance that my identification is correct.

I will start with the ones I think I have identified and would just like some confrimation they are correct:



I believe these are the two connectors for the heater fan twin speed resistor, and for the washer pump



The black and yellow is for the glowplugs, but what is the brown and red for without a connector that comes out of the same piece of conduit?



Is this one for the dim dip resistor? the loom is for dim dip that I plan on using a dim dip bypass relay for so Do not think I actually need this one?



Is this the plug for the engine loom? If so it is very different to the one I hvae for the 200tdi discovery loom currently fitted So I may need a new engine loom (the existing donor one has been cut about a little). Will a 300tdi engine loom fit a 200tdi engine with minimal modification?


The ones below are now ones I hvae no idea what they are for or where they should connect to:



EDIT: Is this one the brake light switch?



EDIT: Is this one the brake level switch?

The other thing I have not identified yet (may be one of the unidentified above) is the diff lock switch wiring? Can anyone tell me what that should look like on a 300tdi and where I would find it on the main bulkhead wiring loom?

Similarly I cannot find the reverse switch wirng? I have an LT77 gearbox so I know the reverse switch circuit will need to be modified and extended to reach the switch on the back of the gearbox as opposed to the side mount on the R380.

miktdish said:

I've been looking at these after breaking mine t'other day .....

They are part # AMR4741
Around £50

https://www.lrworkshop.com/parts/AMR4741
https://www.lrparts.net/amr4741-cover-wiring.html
Mr Blanchard has some (used) @ £20 ... I am going to repair mine

Click to expand...

Many thanks I will order one form Blanchard. the price of some part is horrifying. I looked at the heater far twin speed resistor today as the one fitted tot he donor heater box has had the connector cut off and replaced with blue spades. They are £160! The one on my fire damaged bulkhead looks like the connectors are ok even though the resistor looks a little crispy so think I will solder my old one on the make things connect!

Have you considered buying a load of good quality automotive wire in various colours; a slack handful of relays, a modern blade fuse box and a 12v indicator flasher can and making your own loom from scratch.

You won’t have to worry about matching new to old, nonsense multi pin connectors, can simplify it and route it all sensibly through pond wire conduit or similar (given what’s happened—and having watched the lengths you’ve gone to to rectify it, impressively!) that’s what I would do…

It would also be significantly cheaper…

Pillar said:

Have you considered buying a load of good quality automotive wire in various colours; a slack handful of relays, a modern blade fuse box and a 12v indicator flasher can and making your own loom from scratch.

You won’t have to worry about matching new to old, nonsense multi pin connectors, can simplify it and route it all sensibly through pond wire conduit or similar (given what’s happened—and having watched the lengths you’ve gone to to rectify it, impressively!) that’s what I would do…

It would also be significantly cheaper…

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I did consider that and it would possibly Be cheaper. But looking at others who have made their own it is a huge amount of work. By the time I am done all the vehicle wiring looms will be new replacements which I am Then feeding through conduit for additional Protection. This has the advantage of keeping things standard for any future work/replacement parts required.

I am making my own loom for the additional accessories (three sets of spot lights, electric fans, winch, winch/vehicle isolators) I have just ordered the parts needed for that with a fuse board and relay boxes to mount in the battery box and will make up and wrap looms to the switch gear in the dash.

I am at the stage now in the rebuild where I am connecting up and fitting the wiring loom. Unfortunately my donor bulkhead did not come with the glow plug timer relay and my existing on is a little crispy:



These seem to be rather an expensive item so I would like to only have to buy one of them and have it last. Paddocks are offering it for £38 inc vat (link) which seems to be about right but does anyone have any experience on the quality of these or a suitable alternative that is a quality itme?