Tutorial on 1.6td(jx) Engine Bay electrics

[lucian]

Hullo
I'm in the middle of a wiring job myself - I've been forced to upgrade my wiring to the modern style fuse box.
Dash and fuse box easy enough but the main loom from the back has a larger entry grommet into the dash area.
Do you have a photo of this area so that I can see it's entry point and any pics that show the connections for the other wires that are not connected to the blocks?

I've sorted out the rear end wiring and am doing a simplified wiring diagram, once all done and working will put it on here.
It will make the jobs like yours easier to do that's for sure.
My e-mail is ian-lester@lineone.net.
All the best.

[carpmaster]

"No I haven't..I'm afraid..I haven't even looked at the front Fuse box and relays..this Sat hopfully once I have work out of the way...Best option for you Ian is to Start your own thread showing photos of the areas your interested in...There are club members on here that are more than happy to help and have oodles of experience to hand...more often or not its always best to give Wiki and Archive a go...the 1.6td(Jx) engine bay electrics is a thread to help teach me and others who own a 1.6td to hopfully understand what is what in their engine bay and what I can/need/don't need for the Volvo engine I have been wanting to get started for almost a year...and its been a tough ride...

Get your work and what you have done to date posted..give members a chance to get a feel for what you have done...not only does it show and demonstrate your talents and efforts put in..it also shows you are here to give bit as well as take a bit.

All the best to you too..get your work posted tonight and you could have an answer in a day or so....call me old fashioned..introducing yourself and saying Please and Thank You works wonders.
Tom

[carpmaster]

I have worked out the red and black wire I have labelled to the starter motor is correct and according to Bentleys and the flick below connects to terminal 50 on the starter solenoid. for reference page 27.13

I need to establish a new ignition switch wire for the Volvo ignition coil terminal 15 and I was wondering if I could make one/make use of using terminal 16 on the starter solenoid.
I have since learnt that its's a no no on using the starter..It is highly likely I would burn the Ignition coil through..possibly cause a fire of some description.. feel a right plum...if you don't ask you don't find out and if you don't find out you don't learn..I need to look at connecting to first turn on the ignition terminal...for example what Weldore did for me when visiting the van and turning the key first stage..(not turn over/start) oil light on, alternator on..glow plugs warming up and light going out after so many secs...water level warning light flashing and then going out are all fed I believe from the first stage ignition turn..I need to establish/learn where what that is and tap into it...

Exciting times when it comes to connecting up the wires.. doesn't stop me thinking about the possibilities of having to replace the Clutch master cylinder though...doh!
Thanks for looking and your help...
Tom

[weldore]

for your ignition wire to the coil could you not use the one from the diesel pump solenoid..the one we discussed earlier about using for the fuel cut off solenoid.you could use this wire as a signal wire and run it to a couple of relays which would supply power to both the coil and the cut of solenoid ...perhaps?

just for testing the system you could(i think)just tap off the wire so it powers both the solenoid and the coil .then when all is good do a proper job and make it 2 circuits with the relays

[Hacksawbob]

Sounds like you haven;t seen this.
http://www.syncrosport.com/wiring_diagr ... _KY_JX.pdf" onclick="window.open(this.href);return false;

[carpmaster]

Excellent..thanks for your help...I will take it to work tonight..there is this chap that worked for BMW and is the Bees with wiring diagrams..he said he would help..I will keep you posted..
Thanks again
Tom

[carpmaster]

A big thank you to Hacksawbob who posted the PDF..
It has helped a great deal and after several hours of studying what I have-need and don't need I began work.. I also used Haynes manual 3452 as a cross reference because I needed to establish connections for the ignition coil and solenoid cut off valve.
In the first flick everything which has a hashed/dotted line connection I have disconnected. Both relays for the glow plug and secondary coolant pump are now gone.
Working from left to right on the flick T3/3 which is connected to D15 on the relay plate I have used to connect to the ignition coil terminal 15.
T7a/6 has been disconnected at the engine bay.
T3/2 has been disconnected at the engine bay.

Bottom right I have written a comment about the solenoid cut off valve..My first error ..I didn't completly trace back through the flow diagram when cross referencing with haynes...I actually need to tap into T3/3..I will be sorting that tomorrow...

The second flick shows T7a/5 which is connected to E12 on the relay plate (goes to rev counter) I have used to connected to the ignition coil terminal 1. Again I used Haynes as a cross reference (1.9 petrol carb).


The third flick again working from left to right T7a/7 has been disconnected at the engine bay.
T7a/1 I have used and coonected to the oil pressure switch on the Volvo 0.3bar....When I turned the key (not engine turn over) The warning light was flashing...could be because I have yet to crank up enough pressure..or it could be that I have used the wrong one..something I will study later.

Back in a minute jumping post...

[carpmaster]

The fourth flick working from left to right...
T7a/4 I have connected to the golf mrk 4 header tank..Currently when I turn the key (not starting engine) warning light flashes and then goes out (telling me the level of coolant is OK)...it's meant to flash all the time at the mo..I have no coolant in the system yet! I have connected the two wires up wrong from jx header tank wiring to Mrk4 header tank...Hopfully by swapping them around I will solve the problem.
T7a/2 I have used and connected to the Volvo temp sender. Open to further investigation as I have never had a temp reading.


Here is a flick of the fuse box and connections the van has..had to give it a good dust down..

I havn't messed around with the connections but curious as I am noticed this little puppy tucked away...not easy getting a flick part number
251 919 505 12v 70A..I believe it is for the radiator fan 2nd stage...Another area I need to investigate..when I lost the jx engine last year and it over heated..not once did I hear the Radiator fan kick in!

To finish off I took a flick of the starter motor..One reason is I needed ask a member who has the same to confirm the spade connections..I would like to know what the perpendicular spade connection would be used for...
The red and black wire I have (now) connected to the lower spade horizontal connection I believe is marked 50...its not connected as shown in the photo.

Thanks for looking and your help
Tom

[carpmaster]

Hello
I have tried looking on ebay etc..can a member please recommend the correct/ideal electrical tool that will easily remove the connected ends on the plugs conected below and for removing the ones in the back of the relay plate. Pulling them out by hand doen't always work
and would it also be possible for a link for sourcing the connectors..that I can crimp on the end of my wiring and are suitable for both plug connections and relay plate..I hope I make sense..
Thanks in advance
Tom

[Hacksawbob]

Oh please dont say 'flick' instead of pic I am starting to do inspector Cluseu type involuntary jerks every time I read it.

it's meant to flash all the time at the mo..I have no coolant in the system yet!

yes the flash on startup is just a dash based test to show the lights working, not that useful, search angelos posts on the low coolant warning system... get comfy! https://club8090.co.uk/forum/search.php? ... 9&sr=posts" onclick="window.open(this.href);return false;

.I believe it is for the radiator fan 2nd stage

yes correct J101 relay and 50A fuse S42 on current track 117. Notice it has its own thermo switch sensor screwed into the radiator it is independantly operated and has nothing to do with coolant warning/temperature system displayed on dash.

easily remove the connected ends on the plugs conected below

if you mean the electrical bullets from the plastic round blocks then no, I had a look last night I cant work it out either. I saw this site that Martin put up recently might have what you need. you can remake the multiconnector blocks up with un-insulated tanged male and female connectors that push into the connector blocks.
http://www.autoelectricsupplies.co.uk/" onclick="window.open(this.href);return false;

I would like to know what the perpendicular spade connection would be used for

Not sure about that, on the diesel at least it is not used just there as a spare might be useful for diagnostics when the starter is not working properly!

[carpmaster]

Thanks for your help Hacksawbob..I will mention photo next time..don't want you causing yourself a mischief..
Tom