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dead van diagnostic tools, wiring bypass
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crazyvwvanman
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PostPosted: Thu Jun 06, 2019 9:29 am    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

Those should be ok. The diodes I originally chose were just ones commonly in stock at RadioShack stores at that time. Back then RadioShack stores were everywhere so you could just buy what you needed the same day you wanted it. There are lots of choices now online.

Mark
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vanmarc
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PostPosted: Thu Jun 06, 2019 8:32 am    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

Great tool. I'd like to take make one and keep it packed in the van.

These 6amp diodes could work in place of the Radio Shack diodes, correct?


https://www.amazon.com/NTE-Electronics-GI754-Recti...amp;sr=1-3
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16CVs
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PostPosted: Sun Feb 11, 2018 12:12 am    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

Have you swapped in a known working ECU?
Have you pulled the injectors and checked them for spray?
Have you pulled a plug and checked for spark?

Maybe some Photos might help, there may be something glaringly obvious that is being missed.

I've just finished messing with this system and feel quite familair with it.

Stacy
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1989 Syncro Tristar Triple knob "Swedish"
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joebus
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PostPosted: Sat Feb 10, 2018 11:58 am    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

Gents,
I used the tool, still no success, please help, what should be checked next? Any advice????
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joebus
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PostPosted: Thu Feb 08, 2018 2:49 pm    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

Yes Sir, true, very few!
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Alan Brase
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PostPosted: Wed Feb 07, 2018 10:27 am    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

joebus wrote:
Hi,
Let me also jump in here, have a similar issue with my van, bought recently (2 weeks ago) and was told by previous owner it overheated, tried starting it but discovered no FP sound, fixed that, when cranking, discovered water running out from above pushrod tubes (Welsh plug rusted a hole in it), pulled the tops to sort that, but before that, tried cranking it, it sort of started, but does not run and dies immediately! I am closing the engine tomorrow, where can I start looking for solution with this short background? Really eager to get it running in order to diagnose other issues.
Thanks, any advice will be valued!
Cheers

This is a 2.1? Precious few 2.1 wasserboxers in Namibia, I think!
Al
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Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home
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joebus
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PostPosted: Wed Feb 07, 2018 6:50 am    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

Hi,
Let me also jump in here, have a similar issue with my van, bought recently (2 weeks ago) and was told by previous owner it overheated, tried starting it but discovered no FP sound, fixed that, when cranking, discovered water running out from above pushrod tubes (Welsh plug rusted a hole in it), pulled the tops to sort that, but before that, tried cranking it, it sort of started, but does not run and dies immediately! I am closing the engine tomorrow, where can I start looking for solution with this short background? Really eager to get it running in order to diagnose other issues.
Thanks, any advice will be valued!
Cheers
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Alan Brase
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PostPosted: Sun Feb 04, 2018 12:16 pm    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

Sounds like you're on the right track! What I meant to stress was that if you have a bad connection, it does not need to be totally open for it to cause problems. I'd guess as little as 4 volts lost across a connection may cause the relay to not function.
So a test light may not be as good as a digital device for troubleshooting. The light may not indicate at 4 volts but the digital meter certainly would.
In my case the terminal was still firmly crimped, but the conductors were green at the end of the insulation.
Incidentally, that same car is now failing to start again. Maybe I take my own advice and look at every wire connect exposed to road salt?
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Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home
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16CVs
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PostPosted: Sun Feb 04, 2018 11:49 am    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

All of my connections at the relays are sound. As I look at it I think I may replace the ground loops at the body.
To get it running I am using a jumper insid the breakout box clipped onto the stub of the ground wire and clipped to chassis ground.
I checked it with an OHM meter and was getting mixed signals and realize that it goes to the idle control relay and it was stealing ground through the box. I am now going to disconnect the Idle Control Relay and I think I'll find my open.

Stacy
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1987 Syncro Multivan Triple knob (bastard)
1989 Syncro Tristar Triple knob "Swedish"
2013 Jetta Hybrid a true "Zwitter"
Samba member # 14980
Call anytime number 650 722 4914 .
Keep Your van running and upkept tastefully for the love of the hobby.
Don't let your van end up in an "abortions" thread.
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Alan Brase
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PostPosted: Sat Feb 03, 2018 9:54 pm    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

My 87 had almost exactly the same problem: One of the connectors going into the bottom of the relay the wire was almost completely corroded off.
You know you can release the terminals individually from the relay socket?
Seems like it was a brown wire, maybe with a white stripe?
I found mine with a test light connected to ground. When the ground terminal tests hot, something is wrong.After looking at it closely I could see the corrosion. I think all I did was open the terminal up and strip the wire and solder it on.
30 years of salty road driving finally caused a failure.
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Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home
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16CVs
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PostPosted: Sat Feb 03, 2018 8:08 pm    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

Mark's tool rocks. My 91 Westy is coming back out of a 9 year sleep. It was cranking and no start. I jumped the fuel pump and it buzzed, I tested the Halls sensor plug and there was no power and the Crankcase vent Line heater had no power either.
I pluggd the tool in and followed Mark's dirrections and it fired right up. After diagnosis, it is the Ground wire to the fuel pump relay has an open. I can't figure out exactly which one it is on the body behind the coil. I've cleaned them all and added a new wire from the body to the block which was totally corroded away.
If I jump the brown ground wire to the relay it starts right up, pull the jumper and it dies. This is the wire that also runs over to the Idle control relay. I've checked the wire for continuity against all of the ground wire and can not isolate it.
At this point I am tempted to just jump in to it and ground it. The Bentley says that it is at ground point 12. Can anyone ID which of the ground wire go to the Fuel Pump Relay? I have other things to do and it starts right up, but I'd love to solve this mystery.
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1987 Syncro Multivan Triple knob (bastard)
1989 Syncro Tristar Triple knob "Swedish"
2013 Jetta Hybrid a true "Zwitter"
Samba member # 14980
Call anytime number 650 722 4914 .
Keep Your van running and upkept tastefully for the love of the hobby.
Don't let your van end up in an "abortions" thread.
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Paulbeard
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PostPosted: Sat Dec 16, 2017 1:21 pm    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

This kit and a laminated instruction sheet would be a great addition to the toolbox under the bench (or wherever you keep yours).
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mad.macs
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PostPosted: Wed Jul 06, 2016 6:50 am    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

I think the Digi-Key equivalent part number for the Diodes is 6A05DICT-ND
I miss being able to drive to a Radio Shack. The nearest electronics supply store is an Hour away now.

http://www.digikey.com/scripts/DkSearch/dksus.dll?...5881316708
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Jaybird707
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PostPosted: Wed May 18, 2016 5:22 pm    Post subject: Re: dead van diagnostic tools, wiring bypass Reply with quote

Might have to make this for my issue. This should be a sticky.
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Canoli
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PostPosted: Sat Oct 31, 2015 2:40 pm    Post subject: Reply with quote

How did you attach the diodes to the wire?
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crazyvwvanman
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PostPosted: Sun Sep 20, 2015 7:35 pm    Post subject: Reply with quote

You can buy a splitter to add another spade, see photo. Or you can unplug the largest of the black wires and plug the tool in instead while also using the 2 relay bypass leads.
Make sure any black wire you unplug can't touch metal and short out.

Image may have been reduced in size. Click image to view fullscreen.


Mark
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tom-menke
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PostPosted: Sun Sep 20, 2015 6:15 pm    Post subject: Digijet? Reply with quote

I'm trying to diagnose a no-start issue on my 1985 1.9 Digijet. After making this tool and heading out to the van to test it, I appear to not have an empty connection on my coil. All 3 are occupied by black wires. Will this test tool work for me?
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hurricanejosh
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PostPosted: Mon Sep 07, 2015 9:46 am    Post subject: Reply with quote

does anyone know if this bypass would work with an aircooled 2.0, or what modifications would be required? it seems to be just the thing i need to complete my troubleshooting of non-firing fuel injectors.
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Gunldesnapper
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PostPosted: Thu Mar 05, 2015 11:35 am    Post subject: Reply with quote

I am bumping this since this is the first i have heard of this tool. Ill be making one this weekend. You sir are brilliant.
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Mark Lewalski
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PostPosted: Thu Aug 21, 2014 7:30 pm    Post subject: Reply with quote

I was ready to make this wiring tool but did one last inspection...

Yep, waaaaaaaaay up under and on top of the frame, I found my fuel pump wires kind of... lets say... separated.

Seems that a hungry critter chose to chew on those two wires (and the evap canister outlet hose) just to make me work on the van.

A quick snip here, a quick snip there, a crimp or two, and I'm back in business.

But...

This thread led me in the right direction to find the problem.

So thanks again to the Samba and all it's posters.

Mark
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