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Shorted PS switch wire, not pretty
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Robw_z
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PostPosted: Fri Sep 07, 2018 6:26 pm    Post subject: Shorted PS switch wire, not pretty Reply with quote

I took off the lid today to look for a small oil leak and my attention was diverted when I saw this:
Image may have been reduced in size. Click image to view fullscreen.

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


I eventually traced the problem to this:

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


It appears a wire from the PS switch fell off and shorted on the intake. I do recall a week ago a belt started screeching louder than normal after an awkward left turn, I smelled an electrical burning smell and saw smoke but just figured it was the belt which made the smell. It was one of those times I knew I should be inspecting the issue ASAP but was in a hurry.

The "good news" is there are no apparent symptoms to this problem yet, the van has been going fine.

How far does that wire run and how much could be burnt? I'm tempted to just replace the whole engine harness with a good used unit but I'm hoping that's excessive.

Make sure the wires to your PS switch are tight, I was aware that one was loose for years but didn't think it could cause an issue if it became disconnected.

-Rob[/img]
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?Waldo?
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PostPosted: Fri Sep 07, 2018 6:30 pm    Post subject: Re: Shorted PS switch wire, not pretty Reply with quote

It's not an uncommon issue. Good luck with the repair.
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dhaavers
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PostPosted: Fri Sep 07, 2018 6:53 pm    Post subject: Re: Shorted PS switch wire, not pretty Reply with quote

Ugh... BTDT...

https://www.thesamba.com/vw/forum/viewtopic.php?t=...p;start=20

https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

You won't know the extent of the damage until you get in there & have a look.
Yours looks worse than mine, so replacing the entire harness would be a great
option if you know you have a good replacement. I chose to repair mine in
place due to (a) my budget... Embarassed ...and... (b) the multiple wiring changes
in the 86 model year making it challenging to find a plug & play replacement.

Please note the recommendation to (A) add a fuse [7-10a] FI power from the
B+ post in the firewall junction box, and... (B) replace the PS idle boost switch
connectors with INSULATED terminals...PLEASE!

- Dave
_________________
86 White Westy Weekender
"The WonderVan"

<EDITED TO PROTECT INNOCENT PIXELS>
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0to60in6min
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PostPosted: Fri Sep 07, 2018 6:53 pm    Post subject: Re: Shorted PS switch wire, not pretty Reply with quote

yes... for some reasons the PS switch connectors are scary close to the intake manifold... don't ask me how I know since 2 of my vans escaped fire..

for future reference:

- double heat shrink those 2 connectors.

- loosen the big PS hose bolt and turn the switch away from the intake manifold as much as you can.
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Robw_z
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PostPosted: Fri Sep 07, 2018 8:08 pm    Post subject: Re: Shorted PS switch wire, not pretty Reply with quote

This is a 1990 made in Graz model. Are later model wiring harnesses pretty standard?

-Rob
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