Has anyone removed/rewired the fusebox

I'm used to Honda diagrams, which pretty much show everything you need to know about a particular circuit on one page, I can't get on with that Haynes diagram at all.

the trick with the vw diagrams is having the complete set, in the correct order. if you dont have that, you're buggered!

this may help you understand them:
http://www.clubgti.com/showthread.php?173722

The jetta layout I like!

I've found my fog light switch, but no connector, I can't find the fog light wiring diagram in the jetta manual.

I currently have grey/yel and grey/wht

I guess I need an illumination, earth for the bulb…and what else if at all?

Also, where can I get the connector, from a MKII?

ah, the americans dont usually have foglights so thats why its not there. for the plug a mk2 one wont fit a mk1 switch, so you'll need to beg/borrow/steal one from mk1 golf/jetta or scirocco.

the mk2 fog switch has the following pins:
83 - grey/yellow - power input (fusebox B/20)
83b - grey/white - power to rear fog fuse above fusebox
58b - grey/blue - illumination
31 - brown - earth
83a - grey/white - power to front fog (fusebox B/16)

the above is for MK2 with front fogs and a fog light relay. on models without front fogs the grey/yellow comes from M/1. also the mk1 might not be quite the same! but you have the wire anyway just trace it to where it goes. basically it should be live with sidelights and/or dipped beam (on front fogs models the fog lights come on with side lights, models with rear only they only switch on with dipped beam)

OK< thanks.

I will make do for now.

There is no radiator fan relay in the fusebox?  Could I replace the fuel pump relay to work as a fan relay?  Are petrol/diesel fuseboxes exactly the same?

Thanks for the help, invaluable!

no relay for the fan, just a direct 12v feed. there isnt really a need for it but if you wanted one i would mount it in the engine bay next to the batter, that way the load comes direct from the battery rather than via the fusebox. if you use a relay in the fusebox you wont actually gain any benefit since the fan power already comes direct from the live feed inside the fusebox, the same place the live feed would come from if you fitted a relay

all the ce1 fuseboxes are the same, post-82 mk1/cab/rocco, pre-90 mk2 golf, and a few other vws of the same era

You make a good point, but the ECU controls the fan by gounding a relay on my setup [non Vag] that's why I wanted to use a ground controlled relay in the fusebox, so I don't need a seperate relay holder next to the fusebox


I notice that the coil output is unfused too, the original engine had a 30A fuse to it, I wonder if it really matters…

I have to get on with "real work" now, so I;ll get back on this Friday or Monday.

Thanks for the knowledge!

ok, personally id remove that feature as it isnt really required, more wires = more weight

some mk1/2 had a factory fitted after-run system which would trigger the fan if engine bay temps got too hot after shut-down via a thermoswitch near the inlet, this triggers a fan relay above the fusebox. the std fan wiring is left as is that is 12v direct from fusebox, but there is a spade plug fitted in-line with the slow speed wire which the relay is connected to.

what you could look at though is the a/c relay socket #5, see if anything will fit there. note pin numbers for the socket in jetta89.pdf, you have live and earth to sockets 1 and 4, all the rest lead to the rear of the fusebox. alternatively perhaps you could look at a mk3 golf fan control unit mounted in the engien bay, again so no load is taken for the fusebox instead it all comes direct from the battery.

yeah the coil and ecu outputs are unfused on mk1-mk3, its up to you if you want to add some extras in

OK great, I'll look into it.

Just briefly;

socket 4 is powered by fuse 1, how is socket 5 powered, by earthing socket 2?  If so, that is my answer!

basically what you need to do firs is see what switched relays (if any) fit in your spare sockets, then see if the socket pins map to anything useful.

for example socket 4 doesnt have any permanent live feeds from inside the fusebox, so you would have to use one of the feeds to the back. 4 is used for the shift light/mpg gauge btw.

socket 5 has a fused permanent live feed plus an earth so that could potentially be useful, but that depends where the pins end up.

the other thing to be aware of is where the pins actually end up, and what size they are.the rad fan comes from C/7 which is a large size pin, so ideally you want your relay output to be on a large pin otherwise you risk burning out the fan feed on your fusebox plug.

the a/c socket has a few large pins but unfortunately it maps to plug H which is an odd shape, so you'll have to try to locate a suitable plug housing to fit.

one possible replacement could be the horn relay which uses a std switched relay and maps to plug L, you'll just have to run your horn direct to the switch or cleverly map it somewhere else (run horn switch wire direct to B/25 should do it) note that the gti dual horns dont like running without a relay, but the smaller poverty spec single horns are operated without a relay as standard

OK!

Back on it,

The fuse for the rear fogs clips onto the top of the fusebox, tell me, is that housing still available somewhere?  I'd like to put a 30A fuse there for the ignition coil.



Got the switches all working [no rear harness installed yet, but all the front lights are working, and horn]

sure is, 1h0 937 530 - 2.46+VAT (or do what i do and pikey them out of the scrap yard)

Thanks, they come in MkII and early MKIII fuseboxes then?

If so, I'll be popping out shortly

Cheers

Ah, I've also found D23 - Coil [white plug]  is vacant in mine, I guess I'd need one of those pins to install a wire in that location!  Did you say they're unavailable at the moment?

yeah loads of vws use them from mk1-mk3, plus seats of the same age and id assume various audis too?


was the engine loom originally a points ign or diesel? if so that'll be why its empty. you can get the large CE1 pins at the moment from here, Ref: 3-1564:
Terminals for Special Applications: Polevolt Ltd

unfortunately the small ce1 pins are currently not available. i hope they come back in stock as i need them for my wiring loom conversions

Bah, I could do with a couple of the small ones too.
Have you tried here?
http://www.theworkshopwarehouse.co.uk/electrical-assembly/terminals.html?dir=asc&amp;order=name&amp;p=2

I don't suppose you have any offcut wires with the terminals attached?

this one looks promising:
http://www.theworkshopwarehouse.co.uk/non-insulated-terminals-bullets-female-1-6-mm-oslash.html

these look like the larger size ones:
http://www.theworkshopwarehouse.co.uk/non-insulated-terminals-bullets-female-3-5-mm-oslash-293.html
http://www.theworkshopwarehouse.co.uk/non-insulated-terminals-bullets-female-3-5-mm-oslash.html

I have a few mini ones with wire spare but i cant afford to part with them now unless the ones above are confirmed to fit! i only have 10 or bare pins left and if i cant get any more i will need all the spare pins I can get to finish all my wiring looms (currently i have 41 booked, with no sign of the demand letting up )

What are you doing, renewing the wiring?!

I make engine conversion looms, so say mk1 -> abf, mk2 -> 20v etc. i use the old engien loom as a base for the conversion, but i use fresh pins where possible rather than splicing the old loom to the new looms where they join together

I try to avoid using splices if i can help it, i prefer to rip out a whole wire and replace it with fresh if wires are not long enough, or crimp on new pins if the new loom wires do reach the fusebox. hopefully the pins above are correct otherwise I'll have no choice but to start splicing old pins salvaged from spare looms

PITA, OK, let me know how you get on, there's no prices on that site, so I assume it's an account thing.

expensive:
http://iws.fletcherobrien.co.uk/product.php/section//sn/ET409

cheap:
BULLETS FEMALE [ET409] - £9.78 : Hirespares.com - Supplying the hire Industry

amazon!
http://www.amazon.co.uk/Terminals-Bullet-0-5-1mm-Cable-0-50/dp/B0062MIWW8

expensive:
http://www.keighleytradesupplies.co.uk/100360/info.php?p=8&amp;pno=0&amp;pid=2790254&amp;cat=182316&amp;ack=9&amp;search=&amp;referrer=/100360/info.php?p%3D8%26pno%3D0%26pid%3D2789973%26cat%3D182316%26ack%3D9%26search%3D%26referrer%3D%2F100360%2Finfo.php%3Fp%253D2%2526pno%253D0