Electrical nightmare, please help.

baron2211 · 17-02-13, 02:58 PM

Three weeks ago yesterday MY 1987 200 quattro began blowing its 25 amp fuse that controls the AC radiator fan, wipers and indicators.

After much diagnostics that involved disconnecting each and every item that was on that fuse, the problem was traced to the wiring that went into the tailgate. This was replaced and all is well on the fuse blowing.

On reassemble, it was found that the wipers only work on full speed and just stop wherever they are, they do not park. Also they do not come on with the screen wash. It is possible that some of the relays got mixed up during the diagnostic of the original problem. A second set of stalks was tried but made no difference.

Does anyone know which relay should be where in the fuse box or have any other suggestions that may help please.

Isimmo · 17-02-13, 03:44 PM

I don't know where th relays are, but I'd certainly look at the state of them. My S2 fried the wiring to the tailgate and this in turn fried the rear wiper relay, so check any of the associated relays, they could all be in difficulty.

missfire · 17-02-13, 04:24 PM

I can take as many photos as you like of 100 fuse boxes and relay panels, but none have AC, so maybe not much good.

missfire · 17-02-13, 04:30 PM

This looks like the culprit maybe, decent photos down the page. The fusebox lid or the big label inside the parcel shelf under the steering wheel should tell you where to stick it!

http://www.ebay.co.uk/itm/VW-Audi-Se...-/270914110545

missfire · 17-02-13, 04:36 PM

Relay position 9 in the fuse box.

from sjmautoteknikification.

Intermittent function control, but might affect other functions? Dunno.

baron2211 · 17-02-13, 04:56 PM

Cheers chaps. I've just come in from looking at it and now think that part of the problem may be the wiper motor is shot. I tested it off the car and it still wouldn't park in the correct place. I've found a replacement on eBay for 25 quid delivered, so thought that wasn't too bad and ordered it.

After a chat with my brother, he agrees and added that the intermittent relay may also be shot due to the testing and continuous fuse blowing while the fault was being found.

Thanks for the offer of pics Missfire, I'll give you a shout if I need any. I reckon that the lack of ac will only leave an empty space in the box!

I'll keep you posted with progress.

baron2211 · 20-02-13, 07:50 PM

Well the new wiper motor arrived in double quick time and... it is wrong! Arrrgggh!!

. The wiring connector is an awful lot smaller than the one on the car's loom. So back to the drawing board and in the mean time no car.

msh · 21-02-13, 04:40 AM

I'm wondering - how did you tested your wiper motor off the car if you expected it to park? Of course it won't, as it contains 0 electronic parts which could do it. But since you have removed yours, you can open it, clean the contacts, scrape out old grease and grease it to be sure it will work as expected.

As for the goddamn relay - on fusebox cover should be schematic what should be in each place. If you still want to get another relay - find yourself relay number 99 - it's direct fit in old audis, but it additionally have programmable interval. Very often found in mk3 golf, got mine from one as well.

baron2211 · 28-02-13, 12:00 PM

Cheers for that MSH, I was told how to test it by my brother who is a tech with Ferrari, he was under the impression that the motor had a park switch in it, it dies have a permanent live, so this makes sense. We managed to establish that the wiring is ok to the motor.

Nearly 6 weeks off the road now, this is starting to get annoying.

baron2211 · 04-03-13, 05:42 PM

Finally, its sorted! The motor's connections were cleaned up and the gears regreased and some relays cleaned up too. Strangely, the headlamp washers now work too, the never did before; bonus!

17-02-13, 03:44 PM	#2
Isimmo Super Moderator Classic Audi Club Member Join Date: Jul 2007 Location: Sissix-by-the-sea Posts: 15,218	I don't know where th relays are, but I'd certainly look at the state of them. My S2 fried the wiring to the tailgate and this in turn fried the rear wiper relay, so check any of the associated relays, they could all be in difficulty. __________________ 1985 WR quattro, 1985 20vT RallyRep, 1993 MTM ABY S2 Avant. 2010 S3 Sportback.

17-02-13, 04:24 PM	#3
missfire making wooden things Classic Audi Club Member Join Date: Dec 2009 Location: cow land Posts: 8,156	I can take as many photos as you like of 100 fuse boxes and relay panels, but none have AC, so maybe not much good.

17-02-13, 04:30 PM	#4
missfire making wooden things Classic Audi Club Member Join Date: Dec 2009 Location: cow land Posts: 8,156	This looks like the culprit maybe, decent photos down the page. The fusebox lid or the big label inside the parcel shelf under the steering wheel should tell you where to stick it! http://www.ebay.co.uk/itm/VW-Audi-Se...-/270914110545

17-02-13, 04:36 PM	#5
missfire making wooden things Classic Audi Club Member Join Date: Dec 2009 Location: cow land Posts: 8,156	Relay position 9 in the fuse box. from sjmautoteknikification. Intermittent function control, but might affect other functions? Dunno.

17-02-13, 04:56 PM	#6
baron2211 Grown up member Classic Audi Club Member Join Date: Aug 2009 Location: Midlands, or North East Posts: 690	Cheers chaps. I've just come in from looking at it and now think that part of the problem may be the wiper motor is shot. I tested it off the car and it still wouldn't park in the correct place. I've found a replacement on eBay for 25 quid delivered, so thought that wasn't too bad and ordered it. After a chat with my brother, he agrees and added that the intermittent relay may also be shot due to the testing and continuous fuse blowing while the fault was being found. Thanks for the offer of pics Missfire, I'll give you a shout if I need any. I reckon that the lack of ac will only leave an empty space in the box! I'll keep you posted with progress.

20-02-13, 07:50 PM	#7
baron2211 Grown up member Classic Audi Club Member Join Date: Aug 2009 Location: Midlands, or North East Posts: 690	Well the new wiper motor arrived in double quick time and... it is wrong! Arrrgggh!! . The wiring connector is an awful lot smaller than the one on the car's loom. So back to the drawing board and in the mean time no car.

21-02-13, 04:40 AM	#8
msh 4 ring whore! Join Date: Jun 2008 Location: Rucava, Latvija Posts: 3,816	I'm wondering - how did you tested your wiper motor off the car if you expected it to park? Of course it won't, as it contains 0 electronic parts which could do it. But since you have removed yours, you can open it, clean the contacts, scrape out old grease and grease it to be sure it will work as expected. As for the goddamn relay - on fusebox cover should be schematic what should be in each place. If you still want to get another relay - find yourself relay number 99 - it's direct fit in old audis, but it additionally have programmable interval. Very often found in mk3 golf, got mine from one as well.

28-02-13, 12:00 PM	#9
baron2211 Grown up member Classic Audi Club Member Join Date: Aug 2009 Location: Midlands, or North East Posts: 690	Cheers for that MSH, I was told how to test it by my brother who is a tech with Ferrari, he was under the impression that the motor had a park switch in it, it dies have a permanent live, so this makes sense. We managed to establish that the wiring is ok to the motor. Nearly 6 weeks off the road now, this is starting to get annoying.

04-03-13, 05:42 PM	#10
baron2211 Grown up member Classic Audi Club Member Join Date: Aug 2009 Location: Midlands, or North East Posts: 690	Finally, its sorted! The motor's connections were cleaned up and the gears regreased and some relays cleaned up too. Strangely, the headlamp washers now work too, the never did before; bonus!