Calling all electrical gurus (+ Wagner EM Nero DP issues)

[Lloyd]

Did you remove the ballasts at any point? check the plugs are the right way as they can be put on the wrong way around.
Might be worth while connecting them up direct to a battery (one time a 3b is better than a aby/avant)
probably something simple.

Yes, both ballasts have been unplugged. AFAIK they can only be plugged in one way, right? The two little connections have an male/female, female male and the large one has a hooked clip to engage on a little stud on the ballast.

Can anyone decipher that wiring diagram?

[Lloyd]

Put the WG in a vice, slip a bit of tube into the end of the flexy and lean on it (in the right direction) Sorted

There's an idea!

@ Jamo, yes that's probably the easiest way forward.

[djh]

Yes, both ballasts have been unplugged. AFAIK they can only be plugged in one way, right? The two little connections have an male/female, female male and the large one has a hooked clip to engage on a little stud on the ballast.

Can anyone decipher that wiring diagram?

they big plug out the two can go on both ways around, try them the other way around.

[Lloyd]

OK will swap the plugs around and try.

[Lloyd]

From the schematic:

Brown = earth
Yellow with black stripe = Twin Filament Bulb, Left
Grey with black stripe = Side Light Bulb, Left
White with black stripe = Twin Filament Bulb, Left

Does anyone know where I can find the earth connection 119 in the headlight wiring loom?

Also, am I correct to assume that Grey with black stripe = Side Light Bulb, Left = HID?

[Lloyd]

Anyone?

[s2_bo]

Sorry dont know about the loom but if you need new ballast you can get them on ebay for under £10, its worth having a couple spare in the boot for that price anyway..
Mine are internally earthed too and work fine.

[Lloyd]

Did you remove the ballasts at any point? check the plugs are the right way as they can be put on the wrong way around.
Might be worth while connecting them up direct to a battery (one time a 3b is better than a aby/avant)
probably something simple.

Bingo! Thanks for the winning solution.
It was indeed something simple, just like me!

Just the exhaust to fix now. I think I will probably take Jamo's & Jonas_R's advice and just get a new flex pipe made up to fit using the ends of the OEM flexi.

[Rusty]

Make sure it's not under any tension, as I almost cracked the WG part of the DP clean off! If in doubt - get it sorted properly

[Avantus]

My Wagner + k26/27 hybrid asked for 2 gaskets at the flexi to dp connection.

[Lloyd]

@ Rusty, good advice - thanks

@ Avantus, no chance of that helping me. I need to mod the side pipe or flexi.
and will go for the flexi option as it's the easiest.

[Ross]

Hi Lloyd,

I'm assuming after our conversation there was not enough flex in the flexi piece then? As I said, with some bending I was able to get it to accommodate quite a gap on my old Avant but I was a bit worried about the tension put on the small WG-DP pipe. Never had any issues though.

On my Coupe, I had to get a new flexi piece made.

Regarding the lines - I did find they were a bit of an issue, but if you take the front cam covere off and then loosen the rear cam cover, you get that few mm of 'play' that is required. I also had to tweak the centre housing of the turbo. Once in place, retighten and enjoy

I can't remember if I have a spare flexi, but if you needed it one to 'manipulate' as a quick fix, without risk of destroying your stock one, I can have a look.

Ross

[Lloyd]

Hi Lloyd,

I'm assuming after our conversation there was not enough flex in the flexi piece then? As I said, with some bending I was able to get it to accommodate quite a gap on my old Avant but I was a bit worried about the tension put on the small WG-DP pipe. Never had any issues though.

On my Coupe, I had to get a new flexi piece made.

Regarding the lines - I did find they were a bit of an issue, but if you take the front cam covere off and then loosen the rear cam cover, you get that few mm of 'play' that is required. I also had to tweak the centre housing of the turbo. Once in place, retighten and enjoy

I can't remember if I have a spare flexi, but if you needed it one to 'manipulate' as a quick fix, without risk of destroying your stock one, I can have a look.

Ross

Sadly not enough flex. Even with a long bar it's hard to get one side of the tube to touch the DP side pipe flange, at that stage the other side of the flexi pipe is a good 12mm away from the DP side pipe flange.

I will have this flexi cut and re-welded to fit tomorrow. Should be easy right!?!

[Jonas_R]

Yeah any decent welder can do that Should not be a problem.

[Lloyd]

Got the flexi sorted. Not a pretty job but will work just fine.
All I need to do now is fit the 044 fuel pump/relay/filter and 're-plumb' my boost gauge and all is good for mapping.