Fusing / Current Issue Somewhere

[rikky 37]

I'm building a gti6 205 from bare shell and basically its a 1991 J plate 1.6 originally. So dash loom and engine bay loom are 1.6, and engine loom is converted gti6 one.

Got it all running finally - spark, fuel, all ok.

But keep having the second fuse on the left (20/25a from memory) blow in the interior fusebox. Spent all day backtracking, doing tests, continuity and whatnot and trial and error unplugging fusebox plugs. Narrowed it down to the brown 2-pin (red and yellow wires, shown as AA in the fusebox diagram, and has wires 27J and 27A) plug causing it, which the wires go back to ignition and to another plug. Wondering if its anything to do with the fan setup, so leads me to my main question:

I've installed the twin fan full setup - it was a load of earths (5 I think), coolant temp connector, then the two radiator fan plugs (grey), the brown connector from the engine bay loom plugs under the shunt box, the black plug from the twin setup plugs under the shunt box too, then a +12v from the side of shunt box to the battery live.

Does that sound right? Can't see anything amiss. Only thing done I've done in that area is bypass the resistor (canister with white and blue wires) by bridging the wires together. I've not added any relays in the fusebox inside the car, but assume the 2 green ones and the single black one in the new twin fan box do that job?

 

Apart from that it's only really the engine loom that's been touched and that seems ok. I did remove a shoddy immobiliser setup but everything's reconnected properly and done very thoroughly

Any advice appreciated! Hoping its something simple but spent 6 hours today tracing wires as doing tests to narrow the two-pin plug down! Bit late now to be going back to it but literally cannot find anything amiss and it's fusing when switching igniton so somethings drawing power but the engine's disconnected and gone round and round in circles unplugging virtually everything inside the car too.

 

I expected problems so lucky I've had no others until now really..

Edited October 20, 2013 by rikky

[rikky 37]

Hmm having a look at ths thread:

 

http://forum.205gtidrivers.com/index.php?showtopic=56804

 

Making me wonder if it's related..

 

That said, it was fusing with the blower plug underneath unplugged completely and the control fascia unplugged so not sure if something's missing or not. But that plug the 2-pin on bridges off of is the blower motor plug.

 

(replying to myself here but beginning to think it's the heater blower, as i've never heard it work)

Edited October 20, 2013 by rikky

[rikky 37]

apparently it's the ignition feed back into the fusebox that's the issue, I'm told. although doesn't solve my problem!

[Ryan 99]

Are you sure you've got the fusebox plugs connected correctly? Position AA (back right corner) is for the fuel pump and should be a yellow plug with wires 76 and 76A. AA isn't connected to any other circuits in the fusebox - one pin gets 12V from the fuel pump relay, then goes through fuse #14 and back out through the other pin the the fuel pump.

Edited October 20, 2013 by Ryan

[welshpug 1,675]

you've made no mention of the red 2 pin in the engine look that provides the ignition live for the fan system?

[rikky 37]

Ryan - my mistake, sorry, it's position N!

 

engine loom? or engine bay loom? not following.. it's blowing with engine loom disconnected completely. Unless you mean the red plug within the twin fan box, which plugs into the rendunant plug behind passenger light, in which case it's connected anyway

 

I disconnected the fan setup completely and it was still blowing

 

I've partly been relying on a sparky mate who'se done loads of checking for me so anything you can give me in newbie terms will help because I can tackle it then too

Edited October 20, 2013 by rikky

[marksorrento205 80]

Fuse box at fault? Internal short with in it? I have had one or two fail and cause strange things in the past like switching one thing on and something else flash or work as well.

[rikky 37]

No idea to be honest! But I made sure before I took it all apart that everything interior and exterior worked as it should, including heaters and whatnot. We had the fusebox out to check what pin for the fusebox plugs related to the fuse which kept blowing and marked them up, then checked all them plugs to narrow it down for which was causing the blow by testing them

I must admit a few wires on the interior loom have been a bit sorry looking and have been resoldered / rewired where they were broke or damaged. So maybe something's still either broke, or has come apart when putting the wiring back in. Guess taking it out and taking all the conduit off and inspecting it is looking like the best bet?!

The interior is all still accessible without any dash in, but have been checking plugs and made sure earths and the green-wired connector behind the dash in the left corner is connected up still.

Earths behind headlights on both sides are all there and ok, and everything which was earth that was feeble or used them horrid block connectors has been removed and had a nice shiny ring terminal on it instead.

 

One thing is my ignition loom where it connects to the barrel has lost a few bits from it so can't connect it to the barrel, so I've hotwired it for now on a toggle switch and push switch, but the fact it's getting accessories / cranking over says to me that's not the problem?

Edited October 21, 2013 by rikky

[rikky 37]

Took all looms out today and went over them. Found two dark blue wires going to a brown plug - the same plug I queried an alternator wire previously - and they're both "AMP" possibly 69B and 69C, and the wire numbers state brake pad wear indicator, and the wire (two joined wires come out of the plug) are both cut but not shorting.

 

Second thing is the dip dim resistor wiring has two thin brown wires going to it, then its been chock blocked with the two brown wires going to two of the three black wires on the resistor itself. This means one wire from the resistor isn't connected, not sure if that's right or not.

 

Can it be bypassed by bridging the two brown wires to test?

 

Going to test it all at weekend hopefully if I don't suss it out before

Edited October 21, 2013 by rikky

[rikky 37]

Took looms apart and put them back in.. can't see anything amiss whatsoever.

 

Engine is completely disconnected except earth wire to gearbox. Fan fusebox and fans completely disconnected. Everything inside the car disconnected except 4 speedo plugs (bulbs relating to hazards and lights illuminating as they should, and actual speedo illumination is ok).

 

Indicators and headlights (front and rear) working fine with ignition off using hazard switch and headlight stalk.

 

The brown plug on reverse of dash in top left is connected.

 

Still fusing the second 25a fuse - used over 200 fuses now testing it and my supplies are dwindling

[jackherer 543]

I don't know where to look for your wiring fault but these might help - http://www.thetoolboxshop.com/standard-blade-fuse-replacement-circuit-breakers.html

[rikky 37]

Fixed! Turns out the two pin plug which was plugged in was the wrong plug but fit the keyway anyway in the fusebox. Glad it was something simple that got missed first time