Wiring loom replacement project

mrscalex

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Maybe I will be asking too much asking but... you should record a video of the firing it up moment for posterity after all this work I am sure I speak in the name of everyone here when I say ... we'd like to be there !! :)
We did just that with the engine swap project.

We'll give it a go but we may be doing it in the dark :(
 

Jjim

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Excellent work :thumbsup:

Great that it started for you.
 

Mario

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Holy ... Well done haha yeeeesss, that's a massive milestone, hope the dash not coming up is somethings simple. Any more error codes after firing up?
 

mrscalex

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And here's what happened next. Yes, it's totally genuine that's what the fault was! Well along with a couple of poorly latched connectors.

 

mrscalex

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So the only major thing we are left with to snag, well so far - only basic testing done, is that the central locking doesn't work and in fact I heard a fuse blow when I tried it. No idea on that one yet.

Nothing nasty coming up in INPA. Well apart from DSC (ABS) warnings because we haven't done the sensor connections underneath yet. Plus an error to confirm the blown central locking fuse.

Evening sessions are pretty much out of the question now until the spring. The clocks are going back this Sunday and it's getting chilly. So it will only be weekends now and I'm only ever around in Swindon 1 weekend day too. But we got to where we wanted to by the end of Oct.

On Sunday we'll start our full testing. If this goes well we'll get the loom tied in to it's final position. We're doing stuff the following 2 weekends so we'll pick up again in mid-November and fingers crossed have an MOT by the end of that month.
 

Althulas

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Excellent progress more than easy enough to forget about the relays not being installed on top of all those connections.
 

mrscalex

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Excellent progress more than easy enough to forget about the relays not being installed on top of all those connections.
I had it fixed in my mind the loom was supplied complete and self-contained. And it did have all the necessary fuses supplied.
 

Mint

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Brilliant Rob, your sons face was a picture when she started=))
 

mrscalex

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Brilliant Rob, your sons face was a picture when she started=))
Yep. Totally genuine as well. It really was the first attempt. Nice surprise :)

But the main testing job comes in the shape of nearly 100 different checks on all the different circuits and accessories :(
 

Mint

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... the main testing job comes in the shape of nearly 100 different checks on all the different circuits and accessories...
Having followed your various threads Rob, I think you'll enjoy doing all the checks and ticking them off the spreadsheet;)
 

mrscalex

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Having followed your various threads Rob, I think you'll enjoy doing all the checks and ticking them off the spreadsheet;)
I like spreadsheets :) And I like making lists and ticking things off :) Not so good when I have to put a cross instead of a tick though :(
 

Mario

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I hope the central locking is an easy fix, check that the short circuit that you had to begin with on the boot lid loom didn't fry the actuator
 

mrscalex

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Well we only had about 1.5 hours on the car yesterday. Under-17 driving had taken up most of the day light hours and it was flippin cold to stay out too long. No point trying to do fiddly jobs with frozen fingers that don't work. But we managed to test pretty much everything we wanted to and snag the few things that weren't working.

Tail lamps - holders/bulbs missing. Must have robbed them for something else previously and forgotten!
Offiside front indicator - not plugged in
Offside side-light - not plugged in
Courtesy light - small amount of corrosion cleaned up before connecting​

We tested with the direct control (ie cabin switch) and we tested triggering through INPA where possible too.

Now for the troublesome one. The central locking. We blew 3 fuses testing it. And they are the only 25 amp fuse on the car. So my spares stock was getting low. Then James compared what I'd plugged back in with the 3.0 project sitting next to us. I'd got the actuator and contact plugs the wrong way round! One of the few areas on the car where there are identical connectors and you can do that!

We switched them round and now have nicely working central locking. By the locks and the key. And no more blown fuses.

I struggled to get the windscreen wiper motor connector in. That's a nasty one to get in or out. I'll have to try again next time.

And we have the wheel sensors to complete still.

Also a small number of other connections to make. The audio, windscreen wiper/washer system and the alarm siren. But that's about it.

So really we're in re-assembly mode now. Lots to tighten up and put back. And that's before the carpets, console and rear cubby box/lateral trim/roll bars go back in.

Opportunities will be very limited to work on the car now unless we can clear enough space in the garage. This is one of those jobs you need all the doors, bonnet and boot lid open at the same time and that's a challenge inside.
 

Mario

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Titanic effort well done guys, quick question, do you have a list with all the ground points on the car? I think it will be really helpful to have to be able to troubleshoot issues in the future when ground points get corrosion and things start to not work.
 

mrscalex

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Thank you.

There's surprisingly few ground points. I could probably name them off the top of my head but won't risk getting it wrong.

I can make a list. But better still would be checking in the wiring diagram for your year. This shows the ground locations and also tells you what circuits use each ground.
 
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