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human compass
Samba Member
Joined: June 04, 2013
Posts: 457
Location: Flagstaff,AZ
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 Posted: Sun Jul 13, 2025 4:44 pm Post subject: early fusebox puzzle |
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Hey team, I'm hoping you can help me unify a fuse box issue to one circuit.
In my 84, my headlights, fuel pump, and rad fan is out. This happened after I had a no start issue, dropped the panel and found one of the line in pos wires was disconnected and after plugging it back I found that I had to leave the fuse box dropped to make the drive home or the headlights wouldnt stay on.
In the light of day I've inspected all connections to the fuse box and ground trees, and all appear normal. Everything was looking good so I bolted the box back up and lost all the aforementioned accessories.
I'm going to spend some more time tracking this down and was wondering if there was one circuit that could involve all three of these things??
I did quickly replace the ignition switch with no change.
Havent gone after it with a multimeter yet.
thanks electrical geniuses!
_________________
84 Westy Syncro- 3.3L SVX stage 2 tune,subaru gears 6speed with tbd, front locker, porche brakes x4, aux tank, radflo susp |
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Wellington
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Joined: September 21, 2004
Posts: 2009
Location: Montreal
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Ahwahnee
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Joined: June 05, 2010
Posts: 10243
Location: Mt Lemmon, AZ
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| Posted: Sun Jul 13, 2025 9:53 pm Post subject: Re: early fusebox puzzle |
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In case it helps... I don't think the fuel pump is fused.
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human compass
Samba Member
Joined: June 04, 2013
Posts: 457
Location: Flagstaff,AZ
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| Posted: Mon Jul 14, 2025 5:15 am Post subject: Re: early fusebox puzzle |
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thanks everyone.
yeah, the fuel pump part is a mystery. When I run 12v to the pump it works fine and the van runs fine, so the ecu is getting power. I tried swapping out the ecu for a known good and no change there either. fuel pump relay also swapped out for a spare and good. it's something under the dash....
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84 Westy Syncro- 3.3L SVX stage 2 tune,subaru gears 6speed with tbd, front locker, porche brakes x4, aux tank, radflo susp |
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jlrftype7
Samba Member
Joined: July 24, 2018
Posts: 4638
Location: Chicago
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| Posted: Mon Jul 14, 2025 10:27 am Post subject: Re: early fusebox puzzle |
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Looking the wiring diagrams, it appears that you have a Ign Switch [ 15 circuit ] that is pushed onto the incoming HOT side of the fusebox, on a terminal that is bridged with other terminals to provide fuse power . If that terminal, probably a Female pin, is spread open a bit, or loose on the mating male pin, then you'll have an open or loose connection.
With the key ON, to the normal RUN position, you should have 12 volts/battery power at Terminal 15 on the Ign Coil. Do you have that, consistently?
Wiring diagram shows Black/White wire at same Ign Coil Term 15 which is the feed wire for the Fuel Pump Relay COIL/CONTROL hot wire coming into the Fuel Pump Relay. So, if your Ign Coil is getting power, then the Fuel Pump Relay should get its power the Fuel Pump relay coil.
Load or 30, is another circuit
Ground Control of the Fuel Pump and Main Relay, also another circuit, but you already know this since you bypassed your wiring to get the fuel pump to run by directly powering it.
Get out your Multi Meter and see what readings you come up with.
_________________
'68 Westy- my first VW and vehicle/Bus- long gone.- sold it to a traveling Swiss couple....
'67 Type 3 Fastback, my 2nd car- gone
'69 Semi-Auto Stick Shift Beetle-gone
2017 MINI Coopers, our current DDs
‘84 Tin Top - Hilga....Auto |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10497
Location: Sunshine Coast B.C.
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| Posted: Mon Jul 14, 2025 1:22 pm Post subject: Re: early fusebox puzzle |
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| human compass wrote: |
.....
In my 84, my headlights, fuel pump, and rad fan is out. This happened after I had a no start issue, dropped the panel and found one of the line in pos wires was disconnected and after plugging it back I found that I had to leave the fuse box dropped to make the drive home or the headlights wouldnt stay on.
In the light of day I've inspected all connections to the fuse box and ground trees, and all appear normal. Everything was looking good so I bolted the box back up and lost all the aforementioned accessories.
....! |
I see your comments but would suggest disconnecting all batteries then re inspecting the fuse panel very closely for any faults. e.g. a loose or suspect looking male connector on fuse panel.
Pics of parts in question would help but as a guess, it sounds like the wire in question is the one that connects starter battery positive to fuse box; it's the main positive source to the fuse panel; that wire is not fused. It can pull off where it connects to fuse panel when lowering the fuse panel. And, the insulator on that connector can suffer from heat damage. Look closely at the condition of that connector, feel if it's a loose or normal fit to male connector on fuse panel.
My guess is that leaving the fuse panel lowered while driving home enabled the wire from starter battery positive to make a better more stable connection to fuse panel.
Neil.
_________________
1981 Westy DIY 15º ABA
(VW Gas I4)
1988 Westy DIY 50º ABA
VE7TBN |
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human compass
Samba Member
Joined: June 04, 2013
Posts: 457
Location: Flagstaff,AZ
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| Posted: Mon Jul 14, 2025 1:27 pm Post subject: Re: early fusebox puzzle |
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| jlrftype7 wrote: |
Looking the wiring diagrams, it appears that you have a Ign Switch [ 15 circuit ] that is pushed onto the incoming HOT side of the fusebox, on a terminal that is bridged with other terminals to provide fuse power . If that terminal, probably a Female pin, is spread open a bit, or loose on the mating male pin, then you'll have an open or loose connection.
With the key ON, to the normal RUN position, you should have 12 volts/battery power at Terminal 15 on the Ign Coil. Do you have that, consistently?
Wiring diagram shows Black/White wire at same Ign Coil Term 15 which is the feed wire for the Fuel Pump Relay COIL/CONTROL hot wire coming into the Fuel Pump Relay. So, if your Ign Coil is getting power, then the Fuel Pump Relay should get its power the Fuel Pump relay coil.
Load or 30, is another circuit
Ground Control of the Fuel Pump and Main Relay, also another circuit, but you already know this since you bypassed your wiring to get the fuel pump to run by directly powering it.
Get out your Multi Meter and see what readings you come up with. |
Thanks so much! It's a subaru conversion, so no ignition coil and not quite sure where to test that the fuel pump relay is getting power. I do know the relay is located next to the ecu under the bench and that it's good. I'll have to start back tracking that circuit.
Some good news, You called it on the loose terminal. exactly as you said, it was splayed out and after correcting it, I know have radiator fan and headlights again!
I think I'm going to order a new fuse box and spend a fun weekend replacing that and cleaning up wires.
cheers!
_________________
84 Westy Syncro- 3.3L SVX stage 2 tune,subaru gears 6speed with tbd, front locker, porche brakes x4, aux tank, radflo susp |
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human compass
Samba Member
Joined: June 04, 2013
Posts: 457
Location: Flagstaff,AZ
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| Posted: Mon Jul 14, 2025 1:44 pm Post subject: Re: early fusebox puzzle |
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will do, I think I'm going to take this opportunity to replace the 40 year old panel and clean up all wiring.
thanks!
| Vanagon Nut wrote: |
I see your comments but would suggest disconnecting all batteries then re inspecting the fuse panel very closely for any faults. e.g. a loose or suspect looking male connector on fuse panel.
Pics of parts in question would help but as a guess, it sounds like the wire in question is the one that connects starter battery positive to fuse box; it's the main positive source to the fuse panel; that wire is not fused. It can pull off where it connects to fuse panel when lowering the fuse panel. And, the insulator on that connector can suffer from heat damage. Look closely at the condition of that connector, feel if it's a loose or normal fit to male connector on fuse panel.
My guess is that leaving the fuse panel lowered while driving home enabled the wire from starter battery positive to make a better more stable connection to fuse panel.
Neil. |
_________________
84 Westy Syncro- 3.3L SVX stage 2 tune,subaru gears 6speed with tbd, front locker, porche brakes x4, aux tank, radflo susp |
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jlrftype7
Samba Member
Joined: July 24, 2018
Posts: 4638
Location: Chicago
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| Posted: Mon Jul 14, 2025 2:41 pm Post subject: Re: early fusebox puzzle |
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| human compass wrote: |
Thanks so much! It's a subaru conversion, so no ignition coil and not quite sure where to test that the fuel pump relay is getting power. I do know the relay is located next to the ecu under the bench and that it's good. I'll have to start back tracking that circuit.
Some good news, You called it on the loose terminal. exactly as you said, it was splayed out and after correcting it, I know have radiator fan and headlights again!
I think I'm going to order a new fuse box and spend a fun weekend replacing that and cleaning up wires.
cheers! |
My Bad, I didn't see your engine swap in your vehicle description when I first posted.
Does the 3.3 have individual coils on each plug?, or a common coil like the 4 cyl Subaru engines normally used in engine swaps for the Vanagon?
_________________
'68 Westy- my first VW and vehicle/Bus- long gone.- sold it to a traveling Swiss couple....
'67 Type 3 Fastback, my 2nd car- gone
'69 Semi-Auto Stick Shift Beetle-gone
2017 MINI Coopers, our current DDs
‘84 Tin Top - Hilga....Auto |
|
| Back to top |
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human compass
Samba Member
Joined: June 04, 2013
Posts: 457
Location: Flagstaff,AZ
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| Posted: Tue Jul 15, 2025 2:10 pm Post subject: Re: early fusebox puzzle |
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| jlrftype7 wrote: |
My Bad, I didn't see your engine swap in your vehicle description when I first posted.
Does the 3.3 have individual coils on each plug?, or a common coil like the 4 cyl Subaru engines normally used in engine swaps for the Vanagon? |
No worries! It has individual coils. I think I must have an issue with switchable power getting to the relay since this happened while I was screwing around under the dash. I need to figure out where that switchable wire comes off the ignition switch and if it stops at the fuse panel. Again, changing the ignition did not solve the issue. At lease I have lights and rad fan now!
_________________
84 Westy Syncro- 3.3L SVX stage 2 tune,subaru gears 6speed with tbd, front locker, porche brakes x4, aux tank, radflo susp |
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