Right, next installment. I have now trimmed down some parts of the wiring harness and i have also had a quick look at the wiring diagrams to see where to splice in the feeds for the harness.To start with i removed most of the covering from the wiring harness so that the individual wires could be removed. This seems like a daunting process but actually turns out to be fairly simple. The first wires i removed were those associated with the secondary air injection pump. The SAI pump is controlled by one of the 2 relays in the harness, the one in the brown holder.
To remove the wiring i simply removed the pins from the plug. You need to remove the thick red wire coming from the battery, and also the thick red/white wire which goes to the SAI pump plug. This allows the plug and remaining wire to be removed.
From here i went on to remove the wiring from the brown coloured connector (T6) to the starter. This is a medium sized red wire which is covered along its whole length in black heatshrink. The plug on the end is a single pin packard connector and the other end terminates at the brown plug. Again i removed this by removing the pin from the brown plug.
Next i removed the un-needed wiring from the orange connector to a two pin plug, i am unsure exactly what this plug did in the original car however since it does not connect to the ecu at all we do not need it. Again these wires are covered in black heatshrink along their length and then connect to the orange harness connector. These pins can be removed.
See AlsoVolkswagen Golf PDF Workshop, Service and Repair manualsVolkswagen Golf Repair Manual Wiring DiagramsVolkswagen Electrical Wiring Diagrams. EWDGolf 1 Wiring Diagram » Wiring Diagram
After this wiring was removed i made a start on removing some more wiring associated with emissions systems i will not be using. As previously stated i am removing the Secondary air injection, this is used to heat the cat and as i will not be using a cat it is not required. When removing the secondary air solenoid the ecu would normally log a fault code saying that the solenoid is missing or open circuit. To avoid this code we will be fitting resistors to fool the ecu into thinking the solenoid is still there. See this guide on VWVortex :
http://forums.vwvortex.com/zerothread?id=3111538
or this guide on Cupranet:
http://www.seatcupra.net/forums/showthread.php?t=200030&highlight=n112
Because i am going to be doing this and i will not be needing the connectors, i decided to remove as much wiring associated with these systems as possible and then hide the resistors in the loom. To do this i first removed the wiring from the SAI solenoid valve, i cut this up near to where all the blue/yellow feeds for the sensors join together (this will become clear when you strip the covering off the harness).
Finally i did the same with the wiring to the charcoal canister. Again this can be cut back to near where the sensor feeds all join.
And that is the wiring removal complete for the moment.
Most of the feeds for the ecu, along with some sends to the dash, come from these coloured connectors, along with the 14 pin plug on the other wiring harness.
I have listed the pin designations of these connectors further back in the thread, generally these were the same as my harness although there were a few minor differences.
I have now drawn up a list of which of these wires i think is required and where in my CE2 fusebox i might connect them. I havnt checked these connections yet they are purely from a quick loom at wiring diagrams. If anyone notices anything they think is incorrect please let me know.
T6-brown connector
pin 1 -black or black/purple 15 amp fused switched live 15 to ecu T121/3 Y (g1 pin 4, needs fuse)
pin 2 - purple/white ecu T121/65 to fuel pump relay earth Y (g1 pin 3)
pin 3 -starter N
pin 4 - red/green 20 amp fused constant positive 30 to ecu T121/62Y (Y pin 4, needs fuse)
pin 5 - blue/yellow fused 10 amp from fuel pump relay Y (g1 pin 8)
pin 6 - yellow/black fused 10amp from fuel pump relay (fuse shared with T14a/6) Y (g2 pin 4)T14a - 14 pin connector near battery
pin 1 - black to green/black from oil pressure senderN (use original mk2 pressure wiring)
pin 2 -black/green to black/white to speedo senderN
pin 3 - white/blue speed sender to dash N
pin 4 -purple coolant temp sensor (214)Y/M (G2 pin 3, requires resistor to read correctly)
pin 5 - red/purple 10 amp fused switched live to injectors (183) Y ( Z1)
pin 6 - yellow/black fused 10 amp from fuel pump relay (fuse shared with T6/6) Y (g2 pin 4)
pin 7 - brown earth (204) (197)Y Earth to chassis or battery -VE (Edit by mat-mk3)
pin 8 - black/purple 15 amp fused switched live 15Y (g1 pin 10,needs fuse)
pin 9 - brown/white earth for sendersY (G1 pin 1 or 6)
pin 10 -
pin 11 -black/blue to grey/black oil level (165)N
pin 12 - brown/blue to purple/white oil level to dashN
pin 13 -
pin 14 -T10W -White connector
pin 1 -
pin 2 - orange/black to ecu T121/60 canbus high (227)N
pin 3 - orange/brown to ecu T121/58 canbus low (225)N
pin 4 - white/red ecu T121/39 to clutch pedal switchY (Clutch pedal switch in car)
pin 5 - blue/purple to brown/red to ecu T121/28 (3)N
pin 6 -
pin 7 - white/green to ecu T121/30N
pin 8 - white/red to ecu T121/48N
pin 9 - green/purple to ecu T121/67N
pin 10 - purple/yellow to ecu T121/47NT10 Orange
pin 1 - grey/white to ecu T121/43 (229)Y (probably diagnostics K)
pin 2 - green/red to ecu T121/81N
pin 3 - blue/green T121/22 to brake servo control and vacuum pump N
pin 4 -
pin 5 -
pin 6 - blue/white ecu T121/54 to speed signal in dash wiring Y (Hall speed sensor on clocks W pin 1)
pin 7 - green or green/grey to ecu T121/41 connection to air con N
pin 8 - blue/red to ecu T121/40 connection to air con N
pin 9 - green/brown ecu T121/37 to climatronic control N
pin 10 -T10h Blue
pin 1 - brown/white to brown/blue ecu T121/34 to throttle sender T6b/6 Y
pin 2 - green/white to green white ecu T121/72 to throttle sender T6b/1 Y
pin 3 - yellow/green to yellow/green ecu T121/73 to throttle sender T6b/2 Y (Throttle pedal in car)
pin 4 - grey/red to grey/red ecu T121/36 to throttle sender T6b/3 Y
pin 5 - white/blue to white/blue ecu T121/35 to throttle sender T6b/4 Y
pin 6 - grey/blue to grey/blue ecu T121/33 to throttle sender T6b/5 Y
pin 7 -
pin 8 -
pin 9 -
pin 10 -blue/purple auto gearbox NConnections marked with a Y will be used, those with an N will not. In this list i have added the wiring from the 1.8t coolant temperature sender to the dash. This will not work correctly with the mk2 dash although i believe it will with a resistor added. The other option here would be to keep the original digi mk2 sender and wiring and use a hose adaptor like this one:
(image borrowed from mush's build thread on ed38)I think thats about it for the moment, i will update when i have more. Thanks for watching guys and i hope this is of some use to someone.
Cheers, James
