Club 80-90 Forums

I am confident I'll get some help on this forum... I've got a 1992 Microbus 2.5i (5-cyl) and I'm desperately looking for an owners manual for the fuse/relay map/diagram/layout or if some (with the same van) can take a picture of their fuse/relay box (please make sure the cover is open ) and please post it. The fuel pump and relay was replaced and since then, the wipers only goes on for 1 second when the ignition is switched on - same with the fresh air blower. I'm not sure if the mechanic 're-arranged' the relays when he replaced the old fuel relay but since then I got no wipers/blower/demister.

I've serached for diagrams and saw the link to Brickyard... the small fuses are ok, the layout is on the inside cover, but I've got no reference for the relays

Came across this forum while searching for 'paint spraying tips' and found the roller technique interesting - this will be happening soon!

First things first - welcome to 80-90.

Secondly - welcome to the elite! Where abouts are you? We will also need pics of your baby!

Just as a quick answer, here is my relay panel. Be aware that it is a trick one - actually relay 72 should be one location further to the left. Hope this helps.
I'll dig out a relay location diagram and post that shortly.

Thank you, thank you, thank you! This helps! And thanks for the warm welcome - knew I'm at the right place... No fun driving in the Cape Town rain without wipers, no demisted and all fogged up Once again, thanks for your help.

Here is the relay location chart for a 1991 2.5i Caravelle so it has some equipment that doesn't appear on our Microbus's but gives the general idea.



As you are in Cape Town, be prepared for us UK lot to get you chasing up parts for us. Availability for SA specific items is very poor over here. As you can see (just about) on the pic of my relay board, my bus was originally supplied by Barons in Cape Town.

I assume you are aware of the SA Syncro lot?
http://syncrosa.co.za/forum/

Problem solved! Thanks to your pic and 'some' troubleshooting I retraced what was done... I eventually removed the new relay and put back the old one (marked 18 on your pic) - Bob's your uncle! C'mon Cape Town, bring on the rain 'cause my wipers are working again I read youde4's Electrical Fault thread and shook in my pants hoping I don't have to follow the same route Me ain't no car-fixer-come-mechanic

I'm finding Goldwagen http://www.goldwagen.com/betanew/en to be an invaluable part source, they specialise in German parts, especially VW - if I can help, let me know

Once again Wychall, thanks for your help!

Hi guys, just came across your forum and found it absolutely amazing. I have a 92 model, 2.5 microbus (her name is Bessie ). I really need some help. Could you please help me to locate the relay for the fuel pump. I'm having a constant problem with getting her started. An auto electrician bridged the fuel pump to a coil at the back (cost me R700 just for the bugger to run a wire), but now the problem is still occurring and he now says that the fuel pump is busy packing up. I'm not to sure i agree with him, but would like to have the relay checked before buying a new pump. Please help. Craig - Cape Town

Hi Craig. Welcome to 80-90.

The offending relay resides in the rear offside (Right hand) quarter, best accessed from the rear light aperture. Remove the rear light and you'll be able to see a number of relays. There is further access available from within the engine compartment but you will need to remove the coolant header and expansion tanks, then remove the panel carrying the intake air trunking.

The smaller black relay in the pic is the one.



If the relay is presently bridged and you still have the problem then the pump may be to blame. I have experienced some starting problems on the petrol side of mine (usually run on LPG) and traced that down to the pump. When I dismantled the pump (which involved cutting off the casing, effectively wrecking it) there was significant wear in the rollers, hence low fuel pressure. A replacement pump (after-market copy - much cheaper than Bosch) solved all the problems.

HOWEVER - whatever you do, get that bridging wire off before you lose the bus! If something goes wrong with your fuel system at present (accident or similar) it will continue pumping fuel. Combine that with a spark from somewhere and make sure you have sausages ready for the barbeque. The relay causes the fuel pump to stop as soon as the engine stops. Much safer!

Thanks a mil for your prompt response. I will definitely get that wire off. I thought that auto electrician was a bit dodgy..

Hi guys, I really need your help. My van still won't start. I have replaced the fuel pump, rewired the section by fuel pump relay, relay replaced, air flow meter cleaned, but she still won't fire. Help asseblief.

You mention lots of things to do with fueling. Does this mean that you know the problem is in the fuel system and that the ignition side is ok?

Basic checks for the fuel system :
Is the fuel pump running? Note that it will only run for a few seconds after the ignition is turned on. This is the priming cycle which stops again if it does not receive a pulse from the ignition when the engine starts. If you cannot hear (or feel) the pump running then disconnect the wires from the pump and check with a multimeter. It should show a feed when the ignition is first turned on, stopping again after a few seconds.

Now loosen the fuel feed pipe going to the fuel metering distributor then get someone to turn on the ignition whilst you watch for fuel spillage. CAUTION as it is pressurised fuel so only slightly loosen the connection. If no fuel at this point then check the filter and accumulator to trace the blockage.

If fuel is present, then you are down to checking through the K-Jet metering. I will PM you a link to a Bosch Technical Manual covering the K-Jet which will hopefully give you an understanding of how the system works.

Good Luck