6 - Electrical Systems

         6.0 Wiring Harnes Firewall
         6.1 Turn signals
         6.2 Relay block
         6.3 Terminal Block
         6.4 Fuse Block
         6.5 Starter lock out
         6.6 Glow plugs
Kubvan Electric parts

6.0 Wiring Harness & Firewall (added 2019) more to follow as time permits

During the 4X4 wiring rebuild I decided to document as much of the original as I could as I may need it later on one of the other Vans.

It's nopt perfect but will hopefuly help you along, I was surprised to find for the most part the wiring colour codes in the Bentley Manual is very accurate. Pages 156 to 164. If you do not own a copy of this, you had better rush out and buy one it will be the best $50 bucks your ever spent. While you are at it pick up one with the turbo diesel or TDI of your choice, eventually you will want to upgrade and that manual will be helpful too.
Kubvan wiring Harness interior
Click most pictures for bigger format
Fire wall pin out detail
Click for PDF

 

Kubvan Firewall junction engine bay

Firewall main waring harnes to Engine Bay
Kubvan Firewall

Same as left but inside cab
Kubvan Relay block fuse panel

Relays, fuses and terminal block on top left for external lights and more.
     

6.1 Turn signal

This switch has 4 pins, which provide for left turn, right turn, common, and horn. All in one piece

bentley schematic Wiring for this circuit is tricky, Power comes from the fuse block (brown wire) to the hazard switch. A blue wire runs from the hazard switch to the flasher relay. An orange wire runs back to the hazard switch and to the center pin (49a) of the turn signal switch the yellow and greens run to the turn signal lamps. The adjacent schematic from the Bentley Rabbit manual is the most useful piece of information you will find. Click on it for enlargement.
More detail  on this subject later.
kubvan hazard switch Brown         Blue        Red
    NC        Orange     Yellow
    NC        Orange      Green
Photo and pin out are not the best but following the text above right the brown comes from the fuse block, the blue goes to the hazard relay the orange comes from the hazard relay and turn signal switch on the steering column, with the yellow and green going to the turn signal lights in parallel with the yellow and green from the steering column switch.

6.2 Relay Block configuration

kubvan relay block

Relays from the left
1-Still tracing this one, connected to the starting circuit for sure
2-Turn signal/hazard flasher
3-Radiator fan low speed
4-Ignition
5-Horn
6-Radiator Fan high speed



Thinking about modifying relays by adding an LED on the top so you can see which ones are on.
   

6.3 Terminal block

kubvan terminal blockTerminal Block pin out
details soon ,,mostly tail lights 
1-
2-
3-
4-
5-
6-
7-
8-
9-
10-
11-
12-
13-

 

 

 

6.4 Fuse block

kubvan fuseblockFUSE LAYOUT - TOP TO BOTTOM LEFT TO RIGHT
F1- 20 AMP    WIPERS
F2- 10 AMP    BACKUP LIGHTS
F3- 30 AMP    HEATER BLOWER
F4- 15 AMP    SPARE
F5- 10 AMP    GAUGES
F6- 10 AMP    SPARE
F7- 20 AMP    TURN SIGNALS
F8- 5 AMP      RADIO
F9- 30 AMP    COOLANT FAN
F10-20 AMP    HORN
F11-20 AMP    4 WAY HAZARD
F12-15 AMP    STOP LIGHTS

 

 

 

 

 

6.5 starter lock out (Automatic park interlock bypass)

kubvan automatic park bypass

 

After you have modified your vehicle to a manual transmission, you will need to bypass the automatic transmission starter lock out. IE the don't start while in gear dummy lockout.

 

 

 

 

 

 

 

6.6 GLOW PLUGS

kUBVAN glow plug relayGlow plug relay pin out

30 - + 12 volts from Battery

50 - engergize

85 - ground

86 - Pre glow

87 - Output to GLow plugs

L - Glow light on dash

T - Temperature sensor on engine