Stuee's 101 Rebuild

**stuee** · 20th September 2013, 07:33 PM

Camping got canned due to bad weather so its been put off for 2 weeks.

Spent this morning cleaning up the above items and just applied the first coat of paint. The pedal box is only getting spray cans as it gives a nicer finish. I'm using up the rust kill from the paint tins on the drive-line bits because I wont be looking at them closely. They'll end up with a thicker coating but not sure if that will necessarily translate to more durable. One item I wish I had in the car port is a tap and hose. Degreasing items is difficult as I have to take them up the other side of the house and as that's all accessible by the dog I don't like to do it there. Makes cleaning parts a long messy process.

**Sitec** · 21st September 2013, 08:31 AM

Camping getting canned.... That's more time for 101 work!! Deadline to meet!!

**stuee** · 30th September 2013, 07:43 PM

I went to mount the brake pedal assembly and realised that as soon as that goes in its going to be a nightmare to run wires so that last two days I've been hammering out the electrical work under the dash - pulling wires, then removing them again only to pull them back a second time.

It's in a reasonably good state now, I just need to source some nice nylon cable wrap through a mate now, just need to let him know what sizes now that its all complete.

A pic of the wiring in progress, was quite daunting at the start

Close to finished, just need to get everything wrapped properly and fixed in position. I havnt hooked up the passenger side lights or wipers yet, thats why its still messy near the engine tunnel.

Relays for lights wired up and in place. Will look quite neat once all wrapped up.

**stuee** · 4th November 2013, 02:53 PM

A bit of feedback since of got some spare time at work. I've been spending a lot of time on the new wiring and have a few observations.

One the lack of a detailed wiring diagram for the Painless Wiring harness is a real downfall. Its manual is more of a step by step procedure with no decent diagram to back it up. Some items aren't even documented, like should the horn switch feed wire be grounded or fed 12+ volts on the other side of the switch... I've also missed a few cables and only realised when I've seen them hanging somewhere. One that got me was there are two power feeds for the various circuits, both marked the same but different colours and numbers. I connected one then spent a while figuring out why some of my circuits weren't working. Wasn't till I took the mounting screws off the fuse box and turned it upside down I saw what was going on and hooked the next one up.

The other observation is that wiring up a car takes a long time. I thought once I ran the bulk of the harness everything would fall into place quite quickly. I was very wrong, it has taken quite a while to make all the connections, test things, re-run things etc. Also there's a huge amount of connectors, wire for earth cables etc still required.

I'm getting very close now, I've had to order a cheapy cable snake to try and run the tail light harness through the chassis again, otherwise the rest is nearly done, I will hopefully be able to start the engine by the end of this week using the key!

**Sitec** · 4th November 2013, 03:22 PM

Not sure if its of any use to you, but I have a reasonable wiring diagram that pointed me in the right direction several times of late when getting lights, heaters, washers, horns, indicators etc etc working.... If you want, PM me with an email address and I'll take a copy of what I have and send it to you.... Cheers for now, and looking good by the way! Keen to see the finished article as I think you'll be the one that's setting the resto standards!! 👍

**stuee** · 4th November 2013, 04:38 PM

Originally Posted by Sitec

Not sure if its of any use to you, but I have a reasonable wiring diagram that pointed me in the right direction several times of late when getting lights, heaters, washers, horns, indicators etc etc working.... If you want, PM me with an email address and I'll take a copy of what I have and send it to you.... Cheers for now, and looking good by the way! Keen to see the finished article as I think you'll be the one that's setting the resto standards!! 👍

I've got a detailed colour wiring diagram from when I was a uk club member, this has been great for when I am stealing wires for non-standard circuits and figuring out how some things work (6 way lighting switch, hazard switch etc), but I basically don't have the same for the universal harness that is replacing it which is the pain.

Cheers,
Stu

**spongie** · 4th November 2013, 06:00 PM

Spare a thought for me then. I have nothing of the sort as I'm wiring mine completely from scratch.

**DasLandRoverMan** · 4th November 2013, 06:01 PM

Can't be any worse than fitting an autosparks one. I bought the complete set when I rebuilt my old GS and was hugely underwhelmed.

Despite being a 'complete' wiring setup I still had to make up the looms for the headlights, everything for the rear lights from the back of the chassis loom, plus rewiring a couple of the multiplugs as the wires didn't go to the corresponding pins on both sides.
Fair enough I also modded it to accept the efi setup and bypass the I.R. relay, but I still found myself spending about 2 days tracing wires and feeds etc to sort manufacturing faults, not really what I expected when it was all bought.

**lardy** · 7th November 2013, 10:42 AM

Anything that stands out re the wiring hiccups stu let me know.
I am thinking of knocking the 101 again as we are coming back to Perth soonish, be nice to have it running cheers bud

**stuee** · 8th December 2013, 11:23 PM

Haven't been able to touch the 101 for 4 weeks due to work commitments. Just had three days off and have been going at it pretty hard at it.

Rear hubs are rebuilt and back together, diff cover back on and full of clean oil. Locker will have to wait until after its on the road.

Wiring has progressed further, I can start the engine with the key now

, and with the quality wiring it fires up very easily and quickly although I had a few teething problems to sort out along the way. One was that the alternator (and just about every alternator ever made it seems) uses the ignition warning light circuit to help start the generator. Swapping out the indication light with an LED would supposedly meant he alternator would not actually start generating unless it got a good rev or I added a resistor in parallel and a diode to protect the LED. That was all too hard so the original incandescent globe is back in for that circuit.

The second issue which I have parked for this evening was that the starter solenoid goes to ground when not activated. The problem with this is that the ballast resistor bypass comes from here and consequently it kills the ignition only a second or two after starting the engine (once you've stopped turning the key that is). Disconnected it and it started no problems and ran beautifully. Will sort this out later but its not an issue I had with my dodgy starter box when I first got the engine running.

A video of me showing off some of the bits that work on the 101 (silly me took the video in portrait mode on my phone...):
[ame]http://i570.photobucket.com/albums/ss144/stuee69/101FC%20Project/Videos/2013-12-08165806.mp4[/ame]

Otherwise some pictures, the making of a new brake warning switch:

Removing the dash for the first time to fix some mistakes:

Drivers side lights wired up:

Heater blower back in action!

Also lots of little bits done. The wiring is a great moral booster though. Nothing like being able to turn the key and fire up the engine.

Picked up some 1/4" bundy tube on Saturday to start making up the clutch lines. Also have a new flex hose being made up and two fittings on order which should get in next Saturday. I have a new speedo cable and clutch/brake reservoir coming from AJ soon. Then the goal is to move the 101 under its own steam so I can work on the passenger side disk conversion.

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