Electrical's ..... suck

TorxKiwi · 2011-12-11T07:50:33+00:00

I'm working through the list of jobs on 'Sonny' and now have several partially completed while I await the arrival of parts. So I did the next best thing and moved onto the next job, fit new distributor. I went with a Bosch style distributor with vacuum advance, replacing one without the vacuum advance. Carefully following the 'How To Keep Your VW Alive" and Bentley guides I did the alignments; pulley TDC with crankcase split, rotor with cylinder and also did the 'pencil' test to be sure. I then removed the old distributor. I also checked the slot in the distributor drive all was as it should be. In fitting the new dizzy I could only get it seated properly with the rotor at about the '2 o'clock' mark. Have I stuffed something up? I'm not willing to try and fire it up until I at least get a second opinion!! Seeing as I was stuck on that job I did the usual thing ... and moved onto the next job. Oil pressure light and reversing light, who would have though they would be linked. Previous owner had cut both of them, go figure. Successfully traced the oils pressure light wiring and have that reconnected and working, still struggling with the reversing lights. So ... on to the next job. Indicators work on hazard light, do not work as indicators. I'm figuring its a switch issue, not a relay? So ... on to the next job. Tail lights work on low beam and go off on hight beam. No idea, where do I start? There's not a lot of room under a Beetle for a big bloke, need to install a hoist 😉

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 2 Jan 2012, 1:27 pm

#879461

Not a clue what the cause was, it doesn't appear recent. I'll throw a fuse in to be safe. .

"Ownership of a Beetle is not a destination it is a journey."

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 2 Jan 2012, 7:11 pm

#879500

Ok. As a result of all the advice and assistance I now have functional head/tail lights, thanks all.

Next electrical problem. Hazards work, indicators and wipers do not. Indicator switch needs replacing or something simpler?

"Ownership of a Beetle is not a destination it is a journey."

AA003 Custom Title Time!

1,189 posts · joined Oct 2011 · 2 Jan 2012, 7:54 pm

#879509

Check fuse 10 & 12 first.

Is there anything else, brake lights, fuel guage etc

I read it on samba, so it must be correct.

Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!😂

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 2 Jan 2012, 8:49 pm

#879520

Fuses 10 & 12 are good. Fuel gauge is good. Not sure about brake lights, I am waiting for a replacement brake line to arrive so don't have a complete circuit. I assume that it needs the pressure of a complete circuit to activate the switch?

"Ownership of a Beetle is not a destination it is a journey."

psimitar Son of Jim - Creator of Good

2,506 posts · joined Jan 2009 · 3 Jan 2012, 1:45 am

#879546

Have you downloaded the samba diagram to assist you trace things?

If hazards work all 4 corners then tis something to do with the switch. Find the black/green/white wire going into the switch and jumper it to the battery with a 5amp inline fuse to the battery. Now try each direction on the switch and if no light permanently then switch is dead or left/right wires from switch aren't connected. If does work then feed from flashed relay to switch is faulty.

madness is in the eye of the beholder 👍

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 3 Jan 2012, 8:12 am

#879556

I have both a test lamp and a multimeter.

"Ownership of a Beetle is not a destination it is a journey."

vwo60 Veteran Volks Folk

2,036 posts · joined Feb 2007 · 3 Jan 2012, 8:18 am

#879557

Purchase the correct manual for your car with the apropriate wiring diaghram.

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 3 Jan 2012, 8:51 am

#879562

I've downloaded the wiring diagram from The Samba and also have the Bentley handbook. The bulk of the wiring appears to match the diagrams but there have been quite a few modifications, not all great. I was really just seeking confirmation of where it is most likely that the failure is occurring so that I start looking there.

"Ownership of a Beetle is not a destination it is a journey."

AA003 Custom Title Time!

1,189 posts · joined Oct 2011 · 3 Jan 2012, 10:04 am

#879566

vwo60 wrote:Purchase the correct manual for your car with the apropriate wiring diaghram.

Easier said than done.

I read it on samba, so it must be correct.

Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!😂

AA003 Custom Title Time!

1,189 posts · joined Oct 2011 · 3 Jan 2012, 10:32 am

#879570

Pick a suitable earth for your test lamp/meter.
Put ignition on

Put positive side to fuse 12
Should light.

Put positive side to terminal 15 on hazzard switch Green
Should light

Put + side to term 49 on hazzard switch White (off position)
Should light

Put + side to term 49 on flasher relay White
Should light

Put + side to term 49a on flasher relay Blue (blinkers off)
Should light

Try the same for 49a on the hazzard switch Blue and Black/green/white.

I read it on samba, so it must be correct.

Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!😂

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 3 Jan 2012, 4:45 pm

#879614

Ran the recommended routine with the test lamp, light activated on all. Switch?

"Ownership of a Beetle is not a destination it is a journey."

AA003 Custom Title Time!

1,189 posts · joined Oct 2011 · 3 Jan 2012, 5:56 pm

#879627

Put + side to term L on hazzard switch Black/White (off position)
Blinker switch Left, Ignition on
Should light

Put + side to term R on hazzard switch Black/Green (off position)
Blinker switch Right, Ignition on
Should light

I read it on samba, so it must be correct.

Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!😂

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 3 Jan 2012, 7:33 pm

#879646

Okay, progress and again it's a result of all the assistance, thanks again all. Better still I more or less understand what I was attempting to do, rather than just monkey see monkey do, so I learnt something in the process.

Jumped the connections in the socket that the turn signal switch group plug connects to. Successfully activated the horn, dipped headlights, activated left and right indicators and they flashed. Which I guess confirms that the switch is faulty.

Anyone got a spare for sale? How much should I expect to pay?

"Ownership of a Beetle is not a destination it is a journey."

Lucky Phil Wolfsburg Wizard

480 posts · joined Aug 2010 · 3 Jan 2012, 8:35 pm

#879663

TorxKiwi wrote:Fuses 10 & 12 are good. Fuel gauge is good. Not sure about brake lights, I am waiting for a replacement brake line to arrive so don't have a complete circuit. I assume that it needs the pressure of a complete circuit to activate the switch?

Just bridge the terminals at the switch.

psimitar Son of Jim - Creator of Good

2,506 posts · joined Jan 2009 · 4 Jan 2012, 5:45 am

#879700

If you have trouble sourcing the part in Oz give MegaBug in the UK a go. Used to be well stocked with working secondhand parts. Don't see why $30 won't get you a second hand one.

madness is in the eye of the beholder 👍

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 4 Jan 2012, 7:47 am

#879715

'All systems are go.' Thanks everyone.

"Ownership of a Beetle is not a destination it is a journey."

donn Wolfsburg Elder

3,515 posts · joined Nov 2005 · 13 Jan 2012, 11:32 am

#881234

http://www.ebay.com.au/itm/230729663088?ssPageName=STRK:MEWAX:VRI&_trksid=p3984.m1438.l2661

Will this item crimp the standard flat male/female connectors used on vehicle electrics? I'm not sure what the numbers or type of connectors mean.
Thanks
Or is this the type I need?
http://www.jaycar.com.au/productView.asp?ID=TH1829&keywords=crimp+tool&form=KEYWORD

I dream of a day when a chicken can cross a road without being asked for it's motive!

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 21 Apr 2012, 11:03 am

#897883

Okay. Took Sonny in for his roadworthy thinking I'd taken care of everything, how stupid was I.

1. Indicators are flashing at too fast a rate. Checked bulbs all are 12V 21W. I have wired in side mounted LED flashers which I have disconnected. Still flashing too quickly, as though a bulb is out. Same deal when using hazards. Could it be the relay?

2. Park lights aren't coming on, headlights go to low beam at first stage of two stage switch. I'll check the wiring to the secondary small bulbs.

3. I installed one of these exhaust systems
https://www.classicveedub.com.au/cvd_new/part_detail.aspx?parts_id=16612
Apparently he is now a bit obnoxious and too noisy. Stuffed a bit of steel wool into the tail pipes to shut him up. Should be fine to pass.

4. Drivers seat doesn't lock into the upright position ie: can be tipped forward without using the lever. I'll try and have a look at the mechanism and see if I can sort it or otherwise bolt it upright. 🙁

"Ownership of a Beetle is not a destination it is a journey."

psimitar Son of Jim - Creator of Good

2,506 posts · joined Jan 2009 · 21 Apr 2012, 1:14 pm

#897891

1. clean all earth connections as a rusty connector increases resistance and hence the faster flash rate. Heck clean all connectors from the flash relay onwards 🙂

2. sidelights use a pretty awful connection method. Check for 12v at sidelight positive feed. If this is OK then it's corrosion and earthing problems. I fitted modern sidelights with a dedicated earth wire.

3. that'll do 🙂

madness is in the eye of the beholder 👍

TorxKiwi Officially Full-On Dubber

231 posts · joined Jun 2011 · 22 Apr 2012, 4:40 pm

#898075

Replaced relay, indicators now all okay. Think I fried it when fixing earlier problem that required replacing lever/switch.

Park lights fixed. Both bulbs needed replacing but wiring had once again been 'spaghetti'd' to all hell. Fixed a couple of mis-wired circuits and all is now fine.

Steel wool shoved up both tail pipes. Silenced sufficiently to pass inspection. Will pull it out afterwards.

Bolted seat in upright position, rear seat access via passenger door only which is fine.

Fingers crossed that the pedantic bastard doesn't find anything else!! At least I can be certain that it is absolutely roadworthy.

"Ownership of a Beetle is not a destination it is a journey."