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    Thread: Important service tip for early A1's with fuel pump relay on top of fuse panel

    1. Member WackyWabbitRacer's Avatar
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      08-29-2004 11:44 AM #1
      Note: The following information is not documented in any of the A1 Bentley service manuals, and you may want to keep this service tip with your Bentley. The wiring diagrams do not show the following VW engineering change to the wiring of the CIS fuel pump relay.
      Back in the late 1970's, VW was having a problem with the melting/burning of Pin A8 in Socket A on the back of the fuse panel with ceramic fuses due to the high current load created by the CIS fuel pump. Pin A8 provided +12VDC via a BLACK/GREEN wire to the fuel pump and to Control Pressure Regulator and to the Auxiliary Air Regulator.
      What VW did to eliminate this design problem with the melting/burning of Pin A8 was to totally remove the internal circuit of L14 (socket L) to pin A8 (socket A) and install a remote fuel pump socket and extension harness with an auxiliary plug that plugged into socket L.
      Voltage from terminal L13 (socket L) is now routed to terminal #2 of the remote fuel pump socket via a large RED wire of the extension wiring harness.
      The voltage output to the CIS fuel pump is now provided by terminal #8 of the remote socket on a large RED/YELLOW wire to a "pigtail" connector with two RED/WHITE wires on one branch and a BLACK/GREEN wire (ie fuel pump wire) on the other branch of the pigtail connector.
      So if your A1 has the remote fuel pump relay socket on the top of the fuse panel, and you want to test the relay by installing a jumper wire to make the fuel pump run, then do the following:
      Only remove the fuel pump relay from the remote socket and keep the extension plug in the Socket L on front of the fuse panel.
      Using a good light, find terminal #2 (large red wire on back of remote socket) and terminal #8 (large red/yellow wire on back of remote socket) on the remote socket.
      Install jumper wire between terminals #2 and #8 of the remote socket. This will provide a direct +12VDC to the CIS fuel pump.

      So to bypass the fuel pump relay, just pull the relay from the remote socket and install a jumper wire between terminals #2 and #8 on the remote socket on the top of the fuse panel.
      Thanks to VEExDUB for jogging my memory about this wiring change, and the fact it is not documented anywhere in the Bentley service procedure or wiring diagrams. Cheers, WWR.

      WWR
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      to race, jokes to tell, laughter to share, and cold beers to drink.

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    3. 08-29-2004 04:20 PM #2
      THANK YOU!!!!
      I have had problems with my relay and my Bentley manual only made things more confusing... I took it into a reputable VW shop and even they were puzzled...
      I need to print this out and staple it to my Bentley!!! [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    4. Moderator the brit's Avatar
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      08-29-2004 04:54 PM #3
      I was just about to say that veexdub would love to know about this until i say your thanks at the bottom.
      [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    5. Member kyndig's Avatar
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      08-30-2004 06:56 PM #4
      this puzzled me forever as well

    6. Member 16v po boy's Avatar
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      08-31-2004 09:38 PM #5
      excellent thread.
      i had a fpr going bad on my bunny and played hell finding it. the bently was no help. i fooled with it for a few days untill i eventually pulled the fuse box down to find that external fuel pump relay hiding in a nest of wires.
      i posted here seeking help to find my lost fpr with no results.
      this thread should be copied and printed, then taped to everyones tool box that this applies to.

    7. Member dbreid's Avatar
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      08-31-2004 10:49 PM #6
      Ooooooooh. This is Goooooooood. I actually sat down the last time I worked on a car like this and figure this out, but seeing it in black and white is so much nicer.
      :Runs to printer to pick up printout:
      -Dan

    8. Member WackyWabbitRacer's Avatar
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      09-01-2004 01:32 AM #7
      Having worked so much on the race Wabbit with no factory wiring, I had forgotten about the VW wiring change to the Fuel Pump Relay "relocation" on the older ceramic fuse panels until I was helping VEExDUB with his fuel pump problem.
      Guess I had logged this in my memory many years ago but it slowly came back to me after several IM's with VEExDUB. The retrieve time was slow but the data was still intact.
      I have made an entry in the A1 FAQ thread about this. Cheers, WWR.
      WWR
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    9. Member dbreid's Avatar
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      01-14-2005 06:59 PM #8
      Bump, because this is GREAT stuff to know....
      Ask me how I know about the A8 pin....

    10. 01-15-2005 01:53 PM #9
      Excellent advice! I'll go you one better: This info is found in John Muir's "keeping your Rabbit alive" book. Even more interesting, it turns out that VW screwed up the wiring on that jumper cable thing and they had to recall. He shows a way to check your wiring, though I doubt there are any out there that have the wrong wiring, as it was only the first year of this "fix" and only a few cars that had the wrong wiring. My '81 cabbie has this fix, but the wiring is correct.
      Thomas

    11. 01-17-2005 08:30 PM #10
      can i ask for a clarification? is the afterthought fuel pump relay bracket only present on the late ceramic fuseboxes? i am idly thinking about moving to a newer blade fuse setup, but want to make sure i don't get anything odd. for the writeup, WWR!

    12. Member WackyWabbitRacer's Avatar
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      01-17-2005 09:19 PM #11
      Quote, originally posted by chizor »
      can i ask for a clarification? is the afterthought fuel pump relay bracket only present on the late ceramic fuseboxes? i am idly thinking about moving to a newer blade fuse setup, but want to make sure i don't get anything odd.

      As far as I know, the remote fuel pump relay bracket was applicable only to the A1 ceramic fuseboxes. The remote bracket was the most economic solution to the A8 pin problem. Regards, WWR.
      WWR
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      to race, jokes to tell, laughter to share, and cold beers to drink.

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      01-17-2005 09:23 PM #12
      speaking of ceramic fuses,does anybody know where to get them?i dont have any spares and the dealler and napa dont have them and i dred the day i need one

    14. Member eurotrashrabbit's Avatar
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      01-17-2005 09:56 PM #13
      You can also buy the harness from the dealer here is the part #171-971-761B It is $110 from the dealer Let me know how many you want I have a ton of them 10 cents a peice


      Modified by eurotrashrabbit at 9:59 PM 1-17-2005

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      01-17-2005 10:15 PM #14
      This is also documented in 1982 and later editions of Richard Sealy's monumental contribution to the VW community, "How to Keep Your Volkswagen Rabbit Alive: A Manual of Step-by-Step Procedures for the Compleat Idiot", John Muir Press.
      Regards,
      Chia

    16. Member eurotrashrabbit's Avatar
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      01-17-2005 11:52 PM #15
      A great resource

    17. 01-18-2005 06:05 PM #16
      Quote, originally posted by Chia’s_MkII »
      This is also documented in 1982 and later editions of Richard Sealy's monumental contribution to the VW community, "How to Keep Your Volkswagen Rabbit Alive: A Manual of Step-by-Step Procedures for the Compleat Idiot", John Muir Press.
      Regards,
      Chia

      Yes. That's the one I was talking about. My bad. I forgot it was written by Richard Sealy. Excellent book if you can find one. I found one on Ebay for $15. Almost new. The guy was like 20 miles from my house, to boot!
      Thomas

    18. Member TeamTHP's Avatar
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      01-30-2005 02:33 PM #17
      Great Info! Although I just had my relay melt even though I have the remote harness? So now I need a new remote harness.
      Anyone got one?
      Thanks

    19. 02-02-2005 05:13 PM #18
      Quote, originally posted by WackyWabbitRacer »
      Note: The following information is not documented in any of the A1 Bentley service manuals, and you may want to keep this service tip with your Bentley. The wiring diagrams do not show the following VW engineering change to the wiring of the CIS fuel pump relay.
      Back in the late 1970's, VW was having a problem with the melting/burning of Pin A8 in Socket A on the back of the fuse panel with ceramic fuses due to the high current load created by the CIS fuel pump. Pin A8 provided +12VDC via a BLACK/GREEN wire to the fuel pump and to Control Pressure Regulator and to the Auxiliary Air Regulator.
      What VW did to eliminate this design problem with the melting/burning of Pin A8 was to totally remove the internal circuit of L14 (socket L) to pin A8 (socket A) and install a remote fuel pump socket and extension harness with an auxiliary plug that plugged into socket L.
      Voltage from terminal L13 (socket L) is now routed to terminal #2 of the remote fuel pump socket via a large RED wire of the extension wiring harness.
      The voltage output to the CIS fuel pump is now provided by terminal #8 of the remote socket on a large RED/YELLOW wire to a "pigtail" connector with two RED/WHITE wires on one branch and a BLACK/GREEN wire (ie fuel pump wire) on the other branch of the pigtail connector.
      So if your A1 has the remote fuel pump relay socket on the top of the fuse panel, and you want to test the relay by installing a jumper wire to make the fuel pump run, then do the following:
      Only remove the fuel pump relay from the remote socket and keep the extension plug in the Socket L on front of the fuse panel.
      Using a good light, find terminal #2 (large red wire on back of remote socket) and terminal #8 (large red/yellow wire on back of remote socket) on the remote socket.
      Install jumper wire between terminals #2 and #8 of the remote socket. This will provide a direct +12VDC to the CIS fuel pump.

      So to bypass the fuel pump relay, just pull the relay from the remote socket and install a jumper wire between terminals #2 and #8 on the remote socket on the top of the fuse panel.
      Thanks to VEExDUB for jogging my memory about this wiring change, and the fact it is not documented anywhere in the Bentley service procedure or wiring diagrams. Cheers, WWR.

      FWIW my '81 cabby has the remote relay position and the jumper wires.
      Thomas

    20. Member Estate's Avatar
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      02-02-2005 05:41 PM #19
      LOL!! I had saved WWR's post about this to my VWV notebook last year and was in the middle of updating it and moving it to a new folder just a few minutes ago when I saw someone had posted to the original thread. Was a little confused for a minute, thinking I had stepped back about 6 months.
      Rob | A6 | GTI | Tiguan | JSW | Cabrio | Rabbit |

    21. Member eurotrashrabbit's Avatar
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      02-19-2005 09:46 PM #20
      Just won an auction on an NOS harness on Ebay. Those things are $100 new form the dealer.

      Modified by eurotrashrabbit at 9:47 PM 2-19-2005


      Modified by eurotrashrabbit at 9:55 PM 2-19-2005

    22. Member TeamTHP's Avatar
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      02-19-2005 10:10 PM #21
      Dang. I wish I saw that. I just got the plastic relay holder from the dealer and fixed the one melted wire end.

    23. Member eurotrashrabbit's Avatar
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      02-19-2005 10:12 PM #22
      That is why I posted after I won the auction $26.01

    24. Member TeamTHP's Avatar
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      02-19-2005 10:17 PM #23
      haha.... good job!

    25. Member eurotrashrabbit's Avatar
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      02-26-2005 10:48 AM #24
      Here is a better pic of the updated harness

    26. Member TeamTHP's Avatar
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      02-26-2005 03:28 PM #25
      [IMG]http://*****************.com/smile/emthup.gif[/IMG]

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