Arosa electrical installation Self-Study Program No. 51 ACION POSTVENTAa he ope yb enn eid wy Tere eater ee cot tema Noa Ses POE Th Sees Son ata ea ae eee ee imescae? Resioier of bushes names Sareciona, Volume 23682, Follo 1, Pane 58855 va penser ‘Typeaeting and anege TEEPA, GA, Av, 1124- CBOE BaeoroArosa electrical installation The electrical installation of the Arosa is a preview of the tendency in future installations that will be introduced in new models. The main characteristic of this new installation is the decentralisation of the components. This new installation offers many advantages, the most important being the reduction in the length of the wiring harnesses. This advantage is borne out in the reduction in the cost of the vehicle production, and the redu weight leading to an improved performance and reduced fuel consumption. The installation comes with new components such as the connector blocks, the main fusebox, the fuse holder and the relay holder. Repair operations will also be affected in the search for the reduction of their cost, since these operations are more and more frequent due to the inclusion of more and more electrical systems on the vehicle. The cost reduction is achieved due to the fact that the wiring installations can now be repaired with the help of new equipment which has been developed for this task. This equipment facilitates repair and ensures that this repair retains the same quality guarantee as the original installation. CONTENTS Tr LAYOUT OF THE ELECTRICAL SYSTEM ..... a COMPONENTS . 9 a LAYOUT OF THE WIRING DIAGRAM .... 0 WIRING HARNESS REPAIR . 12.13LAYOUT OF THE ELECTRICAL SYSTEM The electrical decentralisation has led to the elimination of the present main and additional fuse connector boxes, which hold the majority of the fuses and relays needed for the electrical system operation. New components are introduced such as the connector blocks, the main fusebox, the fuse holder and the relay holder. The main characteristic of this new installation is the segregation of each electrical circuit, the only connection point being the main fusebox or the relay holder, which are at the origin of all the electrical supply to all the circuits. The fuse holder is a good example of the segregation of the electrical circuits, since it contains 32 fuses, in other words more fuses, which means that every circuit is protected with a fuse. The main fusebox enables all the electrical circuits to be completely protected. against a possible short circuit which could cause great damage to the wiring installation. The new installation has two main wiring harnesses, one for the engine compartment and one for the passenger compartment and it has secondary harnesses for components such as the tailgate, the rear lights, the roof, the door and its motor. The various wiring harnesses can be easily distinguished since their connections are always made in the connector blocks. The following diagram shows the layout of the different components in the new wiring installat on. Engine compartment eonnector blockCOMPONENTS MAIN FUSEBOX The main fusebox is located above the battery and can hold up to 8 fuses for different systems. This new component ensures that in the case of a short circuit, the extent of the damage will be limited to a blown fuse. Up to now many circuits did not have protection and many protected circuits had sections which were not protected against short circuits. An example of this situation could be seen in the alternator charging circuit, and other installations such as the air conditioning, the ABS and the main fusebox connector supply, circuits, etc. On the Arosa, the only circuit which will not be protected will be the starter motor circuit, due to the high amperage required by this component. The main fusebox is prepared to receive four high amperage fusible link type fuses of which three are presently used, and four other flat bladed fuses. ation and amperage of the fusible link type fuses is shown here: 1| Battery charging 110 A 2 | Relay holder supply 80 A 3 | Diesel [| 50A 4 | Airconditioning | relay supply | 30 A And the flat bladed fuses are as follows: 1| ABS - Hydraulic pump 30 A | 2 | ABS - Valves 320A 3 | Radiator fan 20 A 4 | Air-conditioning relay 10 A Another novelty is the battery poles with a new design, which enables a shorter battery wiring loom to be used by eliminating the wire curves on leaving the battery. This layout also enables the main fusebox to be placed on top of the battery. Fusible Tink type use Pa Cover Cio Flat bladed fuse Fusebox Support ps1-02RELAY HOLDER The new relay holder is located on the left side of the driver footwell area, just behind the fuse holder. The relay holder has now three main functions, which are, to hold the relays, to act a connecting unit and to act as the electrical supply base for the majority of the vehicle wiring circuits. The relay holder houses all the relays of the vehicle, these being as follows for the basic specification: = Indicators and hazard warning lights relay. — Wipers intermittent operation relay. ~ Discharge relay “X”. ~ Fuel pump relay (Petrol version). The relay holder also has a support for additional relays or fuses. The additional relays available Connector block “30” Electrical supply output, oO ae \ Battery input “X" Electrical supply output at present are only fitted on vehicles equipped with: — Automatic gearbox. = Air-conditioning. = Folding sun root. — Daylight illumination system. The relay holder acts as a connecting unit by joining the wiring harness of the engine and the passenger compartment. The power supply function is taken care of through bolted connectors located on the lower side of the holder. Three connectors are available, the first one receives the “30” directly form the battery, the second one distributes this signal to the ignition switch and the fusebox, and the third one is the "X" signal for the fusebox.COMPONENTS a ane eS FUSE HOLDER The fuse holder is located on the left fuses, which has led to the need for the side of the driver footwell area, just in front introduction of this new fuse holder. of the relay holder. The location, amperage and applic: The electrical installation requires more _of the 32 fuses are as follows: Application Application 1_[ Electronic management (15) 15 17 [Left parking 5 2_ [Electronic management (20) 70 lights 3. [Carbon cannister ventilation 7S 18 [Reversing lights 78 valve and window washer @_[lonition transformer 15 79_[ Rear foglight and warning light 15 5 [Automatic gearbox 20_|Brakelights 70 Lever lock 10 2i_[Hazard warning lights 70 [Automatic gearbox 5 22_[Indicators 5 control unit 23_[Front wipers 15 7_[ABS contol unit 5 24 | Rear wipers and 70 & |Lambda sensor 5 electric mirrors Injectors valves 25 [Heated rear window 15 3 [Free 10 26 [Instrument panel 5 10_|Free 15 ‘27 [Instrument panel 5 771_[Horn 15 interior light and diagnosis 72_[Right headlight and warning hgnt | _10 28 _[Radio, central locking 5 73__[Left headlight 10 and cigar lighter 14 [Right dimlight and adjustment 70 28 Electric windows, folding 5 of light on right hand side sunroof and air conditioning 15 [Left dimlight and adjustment 10 30_[Ventilation 20 of light on left hand side ‘31_| Registration plate 5 6 [Right parking 5 light lights 32_ [Fuel pump 5 32 au fuse pst-08Earth connection Ge, ® Connector block Support 51-05 CONNECTOR BLOCKS The function of the connector blocks is to join wiring looms and in this way help to decentralise the wiring installation. For this reason, the connector blocks are located at different points, such as in the lower part of the A pillars, in the front part of the rear wheel arches, in the engine compartment and in the relay holder, since this unit also performs the task of a connector block. The connector blocks have different connector characteristics depending on their location. The connector blocks simplify electrical fault finding, enabling us to locate the exact zone of the installation with a failure. The connector blocks located in the front part of the rear wheel arches have no supports and are protected by a padded surround. The connectors on the connector block in the engine compartment are of a new design on manual gearbox vehicles. The reduced size of these connectors, improve their connections. On vehicle with automatic gearboxes, two modular connectors are fitted, one for the engine and the other for the gearbox, due to the need for more wires on this type of vehicle.LAYOUT OF THE WIRING DIAGRAM ae ie ran) zg — 8 2 cee como | 5 cel S163 808 ' + Ht —_—} Relay holder 51-06 u This wiring diagram corresponds to that of the heated rear window and the horn. This circuit can be used as an example to understand the new general layout of the wiring diagrams. The electrical system always starts at the main fusebox which supplies some of the wiring circuits and the relay holder and receives voltage from the alternator. tis important to realise that the relay holder now only carries 4 fuses and two current lines, these being the supply for "X" (75x) and "30". The relay holder acts as an electrical distributor, supplying “30” to the relay holder and the ignition switch and “X” to the fuse holder and the circuits which work with this supply line. The electrical circuits which work with 15" are supplied by the ignition switch, which sends the signal directly to the fuse holder. The fuse holder carries a total of 32 fuses and these are supplied with 30", "15" or "X" depending on the function of each circuit. We can also find the connector blocks on the wiring diagram, these are identified as connectors and can also be traced by their location and colour. Finally the earth points have the same identification as on previous circuits. LEGEND A Batery D Ignition switch E15 Heated rear window switch H Horn button Hi Horn J89_—“X" terminal discharge relay K10 sit $163 $225 za Heated rear window warning light Fuse Fuse Fuse Heated rear windowWIRING HARNESS REPAIR The introduction of the new wiring installation has been accompanied by the presentation of a new wiring repair kit. This kit facilitates and speeds up repair work, avoiding the need to replace complete wiring looms The repair kit enables high quality repairs to be made in the electrical installation which guarantee the same quality as if the loom had been replaced. 51-07 WIRING REPAIR KIT VAS 1978 This kit includes all the terminals, res and other accessories needed to repair the electrical installation. The kit also contains all the tools necessary to facilitate the making of good connections, thus ensuring the quality of the repair carried out. The wiring repair kit VAS 1978 is made up of the components shown in the diagram When making a repair to the electrical installation we should bear in mind the following points: ~The repairs should always be done with yellow wires. ~The repair wires will always have a crimped connector on their end The wires of the Airbag, ABS and parasite protected wires such as the knock sensor, the rpm sender, etc., should not be repaired. In this cases the complete wiring harness should be replaced. = Retain all the components of the original wiring installation whenever possible (retaining clips, sealing rings, etc. ~ Care should be taken when using the wiring repair kit VAS 1978, to ensure that all the parts used are replaced constantly. A spare parts order should be made for these parts, to maintain the repair kit ready for all repair operations.THE ELECTRICAL INSTALLATION REPAIR PROCEDURE IS AS FOLLOWS: Selection of the part required When the wire needing repair has been determined, the part required to carry out the repair should be ordered, taking the following points into account: ~ Cable section, if a cable of similar section is not available, fit the next largest size. — If a connector is fitted, keep the same kind of terminal (normal or gold plated). = If the cable has a thermal protection, use a cable with the same characteristics. Fit the sealing rings according to the cable seetion and the connector size. Cutting the cable The cables affected should be cut in the most appropriate location, taking into account the ease of repair and the location of the connector installed. When several cables are connected, these connectors should be staggered, to avoid increasing the thickness of the loom Connection The connection should be made with the correct connector, taking into account the section of the cable chosen. Three colours are available for the connectors according to the cable which will be used: Red section: 0.5 - 1.0 mm* Blue section: 1.5 - 2.5 mm* Yellow section: 4.0 - 6.0 mm* Different sealing rings are available according to the section, for this reason we should use a ring with the same colour as the connector. The crimping tool to make the connection has different crimping rings according to the section of the cable, and these are also colour coded. The colour chosen should always be the same as the connector selected. Use the hot air gun to heat the connector, causing the heat shrinkable sheath to melt Cables for repairs st-08 Cutting and stripping pliers Crimping pliers 30 around the crimped connection, preventing contact with other components and possible entry of moisture or dirt.NOTESCUSTOMER SERVICE Service Organization Techrical status 11.96. Due to constant product development and improvements, the data which appear in this document ae subject to possible variation. “The booklets for exclusive use ofthe SEAT sales organization. ZSA 23807979051 INGSICD FEB.'97 90-51