Keine Ankündigung bisher.

Restauration der Elektrik - Bericht

  • Filter
  • Zeit
  • Anzeigen
Alles löschen
neue Beiträge

  • Restauration der Elektrik - Bericht

    Hallo an alle!
    Der Bericht is in Englisch da er auch für jemanden anderen gedacht ist. Hoffentlich wird er für euch dadurch nicht minder interessant

    This summer I had that chance to dedicate an entire month to our ’75 Fiat Spider CS1 US reimport. The biggest problem it had at back then was the entire electric harness. Therefor that was what I decided to dedicate my time on.
    From all the projects I have undertaken on this car so far, this was certainly the most “ambitious” and at the same time the one I had the biggest respect from (so far…).
    It should be noted: I do have some clue about electrics, but definitely not in combination with cars.

    So naturally, the first thing I did was to do a lot of research.
    I decided to follow what most recommended (even though I initially intended it otherwise) and:
    1: didn’t plan an entire “rip everything out” rewiring but stuck to cleaning up the mess and repairing the old harness.
    2: printed the wiring diagram on 4x3 pages to have it in a proper size (with and started to trace all wires with the correct colors according to plan. This way I got to know the diagram and following individual lines got a thousand times easier.

    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: Bildschirmfoto 2020-10-16 um 07.44.00.png
Ansichten: 438
Größe: 807,3 KB
ID: 8956
    The plan looking like this was recommended the most and I can totally agree to that!
    (the quality is bad on purpose since I don’t know who holds the copyright…)

    What I worked with: proper crimping tool (proper = CNC milled insert); Molex connectors; soldering where I considered it useful; toothed lock washer at every grounding; cleaning of most contacts; shrinking tubes; tons of zip-ties; reused many old cables and bought new ones for the lightning with 2,5 mm2 diameter; 30A Relays with sockets for the ones I added; etc…

    Next thing to do was “open” the actual harness and “dive” into the mess. I guess, at this point I should mention all the “interesting” things I figured out about the car during the process as well as the ones I knew already:
    1. the EGR-system has been removed by a previous owner, but all cables, relays etc. were still existing.
    2. furthermore, a previous owner has added relays for the starter solenoid etc., but those were later substituted by a somehow more original wiring pattern by someone else (always by adding new cables – nothing was ever removed)
    3. there is a Lada ignition switch installed
    4. there is a new alternator without the neutral-wire (or whatever it’s called in English. It’s the yellow-red one)
    5. the ignition mode relay was replaced by an ignition control module

    Some impressions of how things looked before I started working / at the beginning:
    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: IMG_0068.JPG
Ansichten: 369
Größe: 1,34 MB
ID: 8957
    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: IMG_4128.JPG
Ansichten: 354
Größe: 2,35 MB
ID: 8961
    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: IMG_4260.JPG
Ansichten: 335
Größe: 2,56 MB
ID: 8959
    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: VNNX2049.JPG
Ansichten: 362
Größe: 1,69 MB
ID: 8960

    First up I ripped out most of the interior (not the dash however). Not surprisingly the wiring was one big mess and it was impossible to properly follow a cable from A to B. So next thing up was to start removing all cables that were not connected to anything, as well as all removing all “dead” relays. Furthermore, all cables leading to exterior lights were removed, because I intended to redo that part entirely – it was extremely hacked up. After this surprisingly long challenge, things got clearer.
    Angehängte Dateien
    Zuletzt geändert von taiF; 16.10.2020, 09:15.

  • #2
    What I deemed “unwanted”:
    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: IMG_4466.JPG
Ansichten: 298
Größe: 3,96 MB
ID: 8986

    But due to all the above mentioned alterations to the (electric) system, the wiring diagram I had, turned more and more impractical. Therefor, a new one had to be made that implemented all the little quirks. I decided to go all the way and draw one in inkscape –based on the one I had.

    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: Bildschirmfoto 2020-10-16 um 05.41.51.png
Ansichten: 368
Größe: 165,5 KB
ID: 8987 ​​
    Once again, this plan is “blurry” on purpose. It is not entirely finished yet and I don’t want to spread a version with errors. But once I’m done, I’m happy to share it as basis for everyone who wants to make their own diagram or needs my version.

    Finally, the “rewiring/fixing” could start. First up the “low hanging fruits” like rewiring the lights in the trunk (and cleaning the housing in the process). Next up was fixing the alternator side of the engine bay. Then came the first proper mess with the relays. Next headache was the ignition-switch that I serviced, together with its messed up wiring. Last thing before tackling the fuse box was cleaning up the center console + dash including the radio. Lastly, I installed a new ATO-style fuse-box and made sure the cables are properly connected and isolated. All that was left to do now was to rewire the front lights including the relays for high and low beam. A little addition I made was to connect the side markers between blinker and front lights – I like the idea of it so it was just for fun. “On the way” I added an electric antenna and exchanged the broken watch with a slightly repainted one from Audi/VW (it was 20 bucks and is intended as “temporary” cheap fix).

    Some impressions of the (mostly) finished areas:
    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: IMG_4447.JPG
Ansichten: 314
Größe: 2,46 MB
ID: 8988 ​​
    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: IMG_4461.JPG
Ansichten: 306
Größe: 2,41 MB
ID: 8989
    Klicke auf die Grafik für eine vergrößerte Ansicht

Name: IMG_4632.JPG
Ansichten: 313
Größe: 3,15 MB
ID: 8990 ​​
    Ultimately, I double checked my own wiring diagram with the original one, and after that I checked if every single cable in the car matched my diagram (including colors of course).

    And what can I say: THAT STUFF WORKS !!!

    It was an awesome project I really enjoyed working on. Even though it took far (!) more time than I anticipated/expected. But I was lucky enough to have the freedom of taking the time I needed to finish it.
    Hope you enjoy and maybe it’s helpful to someone! (also happy to answer any questions ​​
    Cheers, Niko
    Angehängte Dateien
    Zuletzt geändert von taiF; 17.10.2020, 21:08.


    • #3
      Hallo Niko,

      ein toller Bericht! Vielen Dank, dass Du deine Arbeit hier teilst.

      Ich bin auch auf der Suche nach einem Schaltbild /wiring diagramm in einer guten Qualität.

      Wenn Du einen Tipp hast, freue ich mich über eine Nachricht.




      • #4
        Hi Jan!
        Danke sehr und gerne
        hab dir eine PN geschickt.

        Zuletzt geändert von taiF; 17.10.2020, 21:04.