2002 Eurovan electrical problem..intermittent failure

Abscate · Last edited by Abscate on Mon Jan 05, 2015 7:49 am; edited 2 times in total

I loaned my MV to a friend for a trip and she reported losing the headlights suddenly for a few seconds, then they came back. If she toggled the high beams, the lights came back on high

I did some wire tracing and since it looked like the common trace was through the turn-signal-dimmer switch I replaced it on this thread..

(Link)

The problem went away for two months then returned. I now hear as relay click just before I lose lights, and now I'm also losing the heater blower and other stuff. It still goes off for a few seconds, then comes back. I can hear the relay click just before the power comes back too.

I'll do some more current tracing but I'm guessing I have a bad load reduction relay somewhere.

More to come

UPDATE - the ignition switch was the culprit here. Part was 40 USD, about 2 hours of dash work to replace.
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jakehenes · Posted: Sun Nov 30, 2014 7:41 am Post subject:

I would look into the ignition switch they are pretty inexpensive and all power routes through it
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Owner and mechanic - riverwest auto.

Abscate · Posted: Mon Dec 01, 2014 5:12 am Post subject:

I ruled that out as the brights come on when toggled, even with the low beams are dark. I'll check the current trace again to see if that makes sense. Maybe the flash to pass feature bypasses the ignition switch and I missed that. That actually makes sense as I think you can flash with the key out.

Thanks for the advice
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Abscate · Posted: Fri Dec 12, 2014 6:54 pm Post subject:

Getting worse. Lights went out for 30 seconds on me yesterday, along with fan blower and wipers. I seem to hear a click just before the accessories die, which makes me think it's a load reduction relay of some kind.

I will evaluate the ignition switch, though.
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Abscate · Posted: Wed Dec 24, 2014 9:44 am Post subject:

Quick update, I managed to hook my VOM into the black/yellow X terminal from the switch and found it was dropping 12VDC to 0, perfectly correlated with the loss of headlights, wipers and blowers.

In addition, I can get it to fail by wiggling the ignition switch and finding places where the X terminal works or drops.

Kudos to jakehens for her/his diagnosis - a little something special in your stocking tomorrow.

Diagnosis - failed electrical part of ignition switch. Picked up a replacement from VW this morning. Will report back with install pictures.

Happy Holidays everyone!
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Vanagon Nut · Posted: Wed Dec 24, 2014 11:06 am Post subject:

Hope the ign. switch is the fix. However....

A relay can develop an intermittent failure mode. When the power issue occurs, try tapping on any related relays. And if possible, wiggle any wires going into that relay. If the power comes on, and-or you hear a buzzing noise from the fuse box area, try to determine which relay is causing this noise. A cardboard tube as a listening device may help. I'm not familiar with EV relays, but if they're similar or same as relays used in Vanagons, you should be able to remove the cover from the relay to inspect it.

Some relays have a printed circuit board design. The solder joints get old and brittle over time resulting in a poor connection between a pin and solder on the PCB. A magnifying glass will help you inspect the part. I have also had a "standard" type older style relay fail in a similar manner.

Neil.

image of "power supply" relay from early model year Jetta. (from my Jetta swapped '81 Vanagon). This power supply relay failure is well documented in the Mk3 forums I've viewed. A similar relay-application may have been used on early EV's and possibly later EV's This type of failure also happened to a programmable intermittent wiper relay on the same Vanagon.

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

fuel pump relay from same jetta swap. Similar in design to those used on Vanagon. You can almost see the failure at a solder joint between hard wire and pin. I would suggest that this is an UN-common failure mode.

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1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN

Abscate · Posted: Fri Dec 26, 2014 5:25 pm Post subject:

Well, I got it done today. Pics to come. I had a tough time releasing the air bag again, but managed to replace the the electrical part of the ignition switch without pulling the steering column.

Opening up the ignition switch clearly showed the failure inside.
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Vanagon Nut · Posted: Fri Dec 26, 2014 11:59 pm Post subject:

Excellent. I'd be curious to see the guts of the failed switch but I imagine the switch design is quite similar to the Vanagon switch.

Were the contacts burned? (arcing?)

Neil.
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1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN

Abscate · Posted: Sat Dec 27, 2014 3:56 pm Post subject:

Burning, burnt contacts, carbon and burnt grease

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Vanagon Nut · Posted: Sun Dec 28, 2014 11:26 am Post subject:

thanks!
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1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN

tds3pete · Posted: Sun Dec 28, 2014 8:09 pm Post subject:

This is a super common Eurovan issue. Anyone with an original switch should pony up the $10 and replace it. It's an easy fix.
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'58 Westy camper-come and gone
'73 Westy-bought new in Holland,now gone
'86 Syncro weekender-come and gone
'79 Westy...Oscar
'95 Eurovan Camper/5 spd...Marsha Mellow

Abscate · Posted: Fri Sep 04, 2015 5:35 am Post subject:

Bump to add the working pics from my gallery during the next Finance call on ITARS

Battery negative cable off FIRST - ALWAYS !!

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