Tutorial on 1.6td(jx) Engine Bay electrics

[carpmaster]

Hello everyone
I would like to ask a few questions and at the same time help others that may have similar problems in the future...I posted some findings on the alternative engine forum (1.6td to Volvo 230a), however I thought it would be a better approach if I posted on here....I have searched the wiki and forum and found several answers..there are a few bits however I am unclear about. I also have a bentley manual..and as you know it's american "colours of wiring is different and the diesel engine covered is CS..Just campers wiring diagram is not the best to follow..no colour indication for the wiring involved and the print itself is poor... Your help and advise, suggestions etc to help me on with my project would be very much appreciated.
I will begin with flicks I took of the electrics and my attempt to identify them..I have labbeled each and every one to the best of my ability and I am hoping it will help others..other than myself..
I have identified the relay on the right...glow plug relay..the one on the left No 53 14I 951 253 B I believe is for my lights ....relays the same as this are used for electric fan, twin horn and fog lamp..(Thanks to Brick-yard for their support section)..I havn't had chance to study the relay/fuse box at the front of the van yet..hopefully tomorrow..ignore me holding the chocky block..these wires were connected to the auxillary battery..I took this picture for future reference for when I rig one up again (I have since disconnected them).


The second flick is an easy one, however I would like to know which ones connect to the golf mrk4 header tank..here is a couple of picks

and the wires I need to connect/join too

back in a second the posting page is jumping about....need to post this first

[carpmaster]

Now for the alternator connections..

The black and red connects to the "W" Connection and the Blue wire connects to the "D"+ as shown here


Please can you explain what the W and D means..I have learnt that one represents an "exiter" wire and comes from the Starter motor which one I don't know..and does the W stand for warning light connection(I will come back to the Starter motor connections later)
The Volvo alternator is shown below...I believe the broken wire from tracing back through the loom is the connection from the Ignition "D"+...the other black cable is the oil pressure switch connection.

Now it gets a little more complicated if your like myself learning..here is a flick of other connections..for now I would like to concentrate on the grey headed switch which "connects" just below/adjacent to the oil cooler and oil filter..I would like to know if I can use this connection on the volvo Oil pressure switch..here goes..it's smack bang in the middle..

It was connected to this below the oil cooler and filter

What I would like to know please, can I connect it to the volvo oil pressure switch 0.3-0.6 bar as shown below..seems logical to me but I need to ask..I lack a little confidence and I do overthink things.."just being honest gov"...the switch on the Volvo is adjacent to the filter and the internal Oil cooler..here is a pick during painting, the oil filter isn't fitted, but you can clearly see the switch

back in a second..jumping post page..

[carpmaster]

Moving on using the same flick above...you will notice just below the grey switch there is a black wire with a label on it wondering if it is for the diesel solenoid cut off switch..it came from here...

I have read the wiring diagrams from both Bently and Just Kampers and I believe they call it an electro magnetic stop control..the diagram suggest there is a connection relationship with the glowplug relay..Can I use this connection to cutoff the solenoid on the Volvo as shown below...just to the right of the carb and top of picture..

Moving on to another connection...In the pick above to the left is the aux turbo pump connection...I won't be needing this so I plan to get rid...is there anything I need to look out for..relays (151)/fuses etc..knock on effects if I disconnect.
Here is a flick of further connections I would like to share...again there is a lot going on...but I will try and explain what I believe I know..

There is a glow plug buzzer bar connection red cable that connected to this..

also in the flick you can see the connections for I think and this is where the confusion lies...I am unsure of these two one could be a glow plug warning light and temp sender for the glow plugs..purley because of the locality..
Adding to the uncertainty is this connection to the far top right with a red connector and what appears to have blue and white and brown cable..again I am unsure what this one does..it was connected to this part of the Jx engine..also To the left is another switch with a blue wire and it was connected just above...I am hoping this switch/sender is for telling me the coolant temperature on my dashboard..it was never connected (snapped) and I never had a temp reading..so if its the case then I can fix it and connect it to the Volvo temp sender switch.

back in a moment..

[carpmaster]

Just a little more before I come to a close...In this picture to the left are x3 main cables which connect to the positive terminal on the battery..One goes to the alternator, one too the starter and one appears to be a main feed to/from the black box in the engine bay..also in the flick is a red and black cable that connects to the starter motor solenoid...unfortunatly I don't have my old Jx starter..I sold it to Campercrazy who was desperate for one..

I need to establish the connections on a petrol starter motor solenoid..I know about the main screw in connection to/from the positive terminal battery and it can also feed the alternator...I believe there are two spade connectors one is used to the alternator as an "exiter"
What would the other spade connection be used for...can I use it to as a cut off for the solenoid or can I use it for the starter coil...I have read it somewhere but I cannot find the info as I write this, so, as you have probably guesed at this point I am shooting in the dark...sorry folks I'm getting tired. here is a flick of the starter I have..when I visit the van tomorrow I will get a closer look at the connections and take a flick...together with the fuse box and relays I have at the front of the van....



Thanks for looking and helping where possible...please add and feel free to contribute...

Tom

[weldore]

the ' w ' is for the rev counter and the ' d ' is for the signal to the dash to put out the charging light once the alternator kicks in..i fink

E D I T..looking again at the alt ..is the D related to the 10mm nut or the spade connection ?..id say the signal to the dash light is the small spade connector with the ' + ' above it

[weldore]

id say you could use the wire from the diesel solenoid on your fuel solenoid on your volvo

not sure about the rest of the birds nest

[weldore]

all you need for the starter is the big old thick red from the battery and the signal wire that should be part of your original loom to the spade connector on the solenoid(the starter solenoid that is)

[carpmaster]

Thanks Weldore for your contribution...I will keep you posted on how I get on tomorrow...going to play around with wiring up and see if I can hear a sound I havn't heard for almost a year...exiting times ahead.
Hopefully I can get some help on the nest of connections I am having trouble identifying....oil pressure and water temp sender is a bit of an uncertainty on the jx connection side epecially with the different connections relating to temp and pressure...
More photos tomorrow....
Thanks again
Tom

[weldore]

this pic shows the forward pointing end of the head with the oil pressure switch top most and the temp gauge sender below as part of the housing


i dont think it will do any harm with these wires to just earth them and see which gauge reacts.when you get the one for the temp gauge itll shoot over to the right
just do a voltage test on them to make sure its not a 12v supply to something..or better still run a 12v bulb in-line with them

this pic is of the top hose housing with the sender that tells the glow plugs how long to stay on.with it being a turbo im not too sure about other conections on this as mines a non turbo


the sender on the oil filter housing is another oil pressure one

you seem to have most of the original van wiring tagged up ok

good luck

[ghost123uk]

Sorry cannot be of much help here as little experience with Diesels.

I can however confirm that =

the ' w ' is for the rev counter and the ' d ' is for the signal to the dash to put out the charging light once the alternator kicks in.

Is correct

And add that "W" for rev counter (whether fitted or not) is also the (blue wire) feed to the system that monitors the oil pressure when above ~2000 RPM in conjunction with the higher pressure (of the 2) oil pressure sensors.

[carpmaster]

I wasn't able to work on the van today...but I have been doing a bit of studying.

Thank you for your help Ghost and Weldore..much appreciated..interesting about the Blue "W" connection wire and its relationship with Revs and oil pressures..

What I can tell you a little history..with Oil Pressure..when my diesel was alive and I turned the ignition first stage (i.e not starting waiting for the glow plugs to warm up) the oil warning light "red" would flash for a few seconds and then go out...what switch/sensor would be responsible for that..The blue single wired switch just above the water temp sender would not be responsible as this had always been snapped/disconnected....So it is either the Pressure switch directly below the oil cooler/filter or its one of the senders adjacent diesel solenoid and buzzer bar..

It will be interesting to find out..If a member has an idea please feel free to share...Weldore (Thanks for the PM) has given me a few tips on earthing out the twin wired connections...for the water temp gauge "which never worked" incidently neither did I ever hear my radiator fan kick in when the engine seriously overheated and blew the head last year...I plan to check the fuse 30A and buy a new relay...

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.

Thanks again for your help Gents
Tom

[weldore]

ive just been out to the van to check what the led's do when you turn the key on and dont try to start it...

(led's in the center block of the dash)

oil stays on all the time
alt stays on all the time
glow plug light goes off after around 5-7 secs

(the led above the water temp gauge)

flashes fast for around 5 seconds then goes out


so you might have been confused with the oil and temp led's perhaps ?

[carpmaster]

Thanks for nipping out to you van and trying that out Weldore...
I probably was confused..it's been a while since I turned the key.... What you have done is given me a guide for the future and what to look out for when I eventually get to wiring up the connections..except of course the glow plug relay warming up the plugs...nice one bud
Tom

[weldore]

So to answer one of your questions...
The led above the temp gauge is connected to the 2pronged sensor that goes into the top of the expansion tank.this tells you if your water level is dangerously low

[weldore]

Thanks for nipping out to you van and trying that out Weldore...
I probably was confused..it's been a while since I turned the key.... What you have done is given me a guide for the future and what to look out for when I eventually get to wiring up the connections..except of course the glow plug relay warming up the plugs...nice one bud
Tom

No probs tom

and please if anyone thinks im wrong do step in and help as i am just going off memory