Serious Problem

[s2avant]

Sods Law strikes again. I replaced the WGFV today and when I came to drive the car this evening another problem has reared it's ugly head.

My indicators, wipers, blowers, foglights, heated seats, heated rear screen and electric mirrors don't work. The windows, central locking, headlamp beam adjust, radio and hazards all still work (although the hazard switch illumination is gone )

My main concern though is that when the ignition is off the cabin is filled with a strong burning smell. I think I may have to disconnect the battery to make sure the car doesn't go up in smoke tonight.

Any ideas what has gone wrong this time? Symptoms point towards the ignition switch but not all ignition fed accessories are affected. The ignition switch was replaced a couple of months ago.

As I say the burning is my main concern, what could cause this? I've never seen a faulty ignition switch cause this before.

I've not got time to go through all the wiring diagrams tonight to see if there is a common connection between the components that don't work so will have to spend time on it tomorrow.

Any suggestions as to where to start looking would be greatfully received.

Ben

[Martynf]

Ben,

surely can only be a short circuit somewhere under the dash I reckon.... guessing of course, but it sounds like a short in the under dash wiring. Have you fitted / moved / screwed anything under the dash recently?

You can feel the electrical ignition switch with your finger tips, so you could tell if it was that getting hot or not?

good luck!
Martyn

[s2avant]

I haven't played with any wiring under the dash for weeks

I've gone through the current flow diagrams (I'd forgotten how disorganised they are ) and think I'm looking at a fault with the x-relief system, either the ignition switch or the relay.

All x-relief components are affected whereas the terminal 15 bits are still working.

I have a feeling one the wires from the igntion switch has been tapped for what I think was the radio wiring so I will have the dash tray out later and have a look at that. It's the only thing besides the ignition switch that I can see would cause the burning.

If its a failed component I'll have to hardwire the x-relief bits so I can drive to work tomorrow and order the bits I need.

Don't you just love problems at the weekend

Ben

[s2avant]

I've hard wired the x-relief relay and everything is working again except the intermittant wipers, and when you pull the stalk to wash the screen it sprays screenwash but doesn't wipe.

The feeds to and from the ignition switch are fine so the switch must have failed. The x-relief relay is in pieces too. Both the switch and the relay have the same burnt smell. I'll replace both to be on the safe side and look into the wiper fault, could be the relay for the intermitent wipers has failed also.

Ben

[Martynf]

What a mare Ben :-( not a lot to say really.... Good luck with it.

In the wiring diag's, have you got one that covers the air con of our cars? I need the ac wiring diagram to track a fault down??

Martyn

[s2avant]

Martyn,

It's in the folder somewhere. There's probably a fault finding guide as well. I think all S2's use manual air con don't they? I'll sort it out for you. PM me your fax number or address and I'll send you a copy. Probably tomorrow of tuesday, depending on when I get chance to go through the binder.

Ben

[porkkis]

All RHD S2's use manual I guess...

Mine has an automatic.

[s2avant]

Why me?

Well it's not the ignition switch. It's the earth side of the relay thats failed.

That means it's either the main terminal 31 earth from the central electrics board or the board itself. Either way it's got to come out to find the problem.

Why can't I have a simple fault like everybody else?

Has anybody any experience with a fault like this? From what I can tell from the wiring diagram the earth side of the board is earthed through a 0.5mm cable!!!

Ben

[Martynf]

Ben... man you have had your share of poo .5mm earth feeding the fuseboard :eek2: that would be a surprise! unless.... the fuseboard picks up earth from its mounting screws into the bulkhead of the car? then a .5mm supplementary earth maybe....

You and I both know, you never, ever supply Audi 80 based fuse boards!

You have to take the board out if you suspect it and check it underneath. Good luck Ben


Martyn

[s2avant]

I'll need it. I can see this becoming a rather involving task to sort out.

I got my nice new shiny ellipsoid headlights today though. Nothing like comfort shopping with someone elses money.

[s2avant]

Right then, may I please ask that everyone can take minute to pray that I can get this problem sorted.

I stuck my head under the dash and sure enough the worst possible situation has arose (no, i'm not stuck, and no my trousers didn't split ). The fuse box has melted!!!! and so have a couple of the connectors going into it.

We're talking off the road till it's fixed. The head lights failed this evening and I can't risk any more damage to the electrics.

I'm going to need a new fuse box, new connectors and new wiring terminals so you can expect a phone call tomorrow Martyn for any back ordered bits.

The only problem is what caused it. That is going to take longer to find than repairing the damage already done.

The earth pins are now running 12 volts so this has become rather more serious than I first thought. God knows how many relays are fried.

Once again, a minute to pray for a swift end to my torments

I'm beginning to regret buying a cheap one. Especially when I could have had an S4(A100) in excellent condition for a grand less.
No you must not think like that benjamin

Ben

[S2central.net]

Oh **** - That is nasty ... be thankful it didn't end up in flames...

Time to be very methodical about this. You never had the problem until changing the WGFV - which should have needed removal of the right headlight. I strongly suggest you have a damn good look and test of all the wiring in that area.

I've seen a couple of places on my car where hasty work and bad luck could cause insulation to be rubbed through - check where the wiring loom runs past the bonnet lock carrier for starters.

This is why I spent ages with extra insulation on my HID install.


Paul

[audiman]

****** hell. Nasty. That sounds like a right bitch of a problem. Bad luck m8. The S2 theory is back in play, in for a penny in for a blank cheque!! Proper *******.

[Martynf]

FOOK

[Martynf]

I wanted to say "Flaming hell Ben" but then thought no . That is a COW. Call me, no problem!