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 Electrical System

 

 Fuse & Relay Panel Diagrams

The Bentley Service Manual has numerous errors in its list for relays and fuses. Most of those errors have been corrected here! However, it's wise to verify your relays using the relay part numbers listed below.

 

The fuse/relay panel is located under the dash, driver's side, behind the kneebar. 

1980-1982 fuse/relay panel part number: 171941821C

1983-1993 fuse/relay panel part number: 171941821D

NOTES:

  • Fuse amperage: Green = 30; Yellow = 20; Blue = 15; Red = 10.

  • The numbers in the relay diagrams are position locations and have no relation to the numbers on the actual relays.

  • 1980-1982 Cabriolets use ceramic fuses.

  • 1980-1982 fuel pump relay: Originally installed in position 7; due to a recall, the relay should have been moved to position 1 with a wiring loom bridge to position 7.

  • If your car has factory-installed heated seats, the relays for this option are under each front seat.

  • If your car has a factory-installed 2-stage after-run cooling fan system ('88-'89), the relay for this fan is mounted to the left front fender.

  • If your car has a factory-installed power windows, there is a control unit beneath the dash on the passenger side.

  • If your car has a factory-installed power top, there is a covered thermo-fuse above the relay panel.

  • If your car has dealer-installed daytime running lights, there may be a relay in or above the top row of the main panel relays (not shown in the diagrams).

  • CE1 panel pin-out schematics

1980 - 1982

Diagram

1983 - July 1987

Diagram

July 1987 - 1989

Diagram

1990 - 1993

Diagram

(Relays in gray are uncomfirmed)

Please do not hot-link any of the above images!

 Relay Part Numbers
Relay Part Number(s)
Air Conditioning 171959141A
Cold-start Enrichment (CIS) 141951253B
Coolant Low-level Warning Control Unit 191919376A
Daytime Running Lights 701919505
Digifant Control Unit 141951253B
Fog Lamp (Europe) 141951253B
Fuel Injection Power Supply (aka Lambda Relay, CIS)

171906381 => 7M0951253

Fuel Pump (1980 CIS)

321906059C

Fuel Pump (1983+ CIS)

321906059E => 321906059F, 321906059G

Fuel Pump (Digifant) 191906383C
Heated Seats 443919533A
Horns 141951253B
Hot-start Pulse Relay for Cold-start Valve 813906064
Idle Boost/Stabilizer Control Unit 811905343
Intermittent Wipers

321955531A => 191955531

Load Reduction

171951253A => 7M0951253A

Power Top Circuit Breaker 443937105
Power Window Control Unit 191959875
Power Windows (Europe) 141951253B
Radiator Fan After-run Control Unit 191955532A
Seat Belt Warning/Door Chime 171919433 => 3A0951307 (also 321919433B)
Starter Inhibitor (auto trans., up to M-35000)

191927181

Starter Inhibitor (auto trans., from M-35001)

191919185

Turn Signals & Emergency Flasher

111953227D, 1H0953227

Time Control Unit (fan, Digifant) 191955532A
Two-stage Radiator Cooling Fan Control Unit 701919505
Up-shift Indicator Control Unit

371279241 => 171919091C

Those part numbers listed in gray with a "=>" after them have been superseded (they are provided as references); current part number(s) for those relays follow them in black. 

 Ground locations

The main grounding locations on Cabriolets:

  • Battery to the left frame rail; frame rail to the transmission

  • Valve cover to the ignition coil

  • Fuse/relay panel

 

 Where to get wiring diagrams

Wiring diagrams can be found in the Bentley Service Manual as well as the Haynes Repair Manual.  NOTE: Those with 1986 Cabriolets should follow both the 1986 and the 1987 Bentley main wiring diagrams; much, but not all, of the wiring in a 1986 resembles the 1987 diagrams.

 

Click here for an explanation on how to read the wiring diagrams (56K warning!).

 

 Warm wires

Warm-to-the-touch wires are not at all unusual in these cars, due, in part, to the way they were wired at the factory.

 

However, wires that become so warm or hot that they melt their insulation and/or smoke are cause for concern.  An overly warm wire is indicative of a circuit with high resistance.  This high resistance can be caused by various issues: bad ground connections, poor wire connections, faulty switch, faulty relay, etc.

 

 Connecting the OBD I diagnostic/scan tool

Under the shift boot, towards the front.

 

NOTE: Only Cabriolets equipped with Digifant I engines have the OBD I diagnostic port; furthermore, an OBD II diagnostic tool cannot be used to pull fault codes from an OBD I system!  

 

 Voltage drop & voltage readings

Voltage drop is a common malady on Cabriolets due to a poorly designed electrical system. Voltage drop can be witnessed on the VDO volt gauge with the engine running: When turning on the headlights, for instance, the volts will drop from 14 down to 12 (the drop is actually more severe when reading the voltage at the battery, then at the headlight; this is because the volt gauge is not 100% accurate); the volt gauge needle will also bounce in rhythm with the turn indicators. If the charging system is in good working order and all ground wires/connections are in good shape, this is nothing to really worry about.  However, to combat voltage drop (and to increase headlight output), install headlight relays, clean all ground contacts and replace ground cables. 

 

Voltage readings:

  • Key-off battery voltage should be 12.6V with a surface charge; 12.3V without a surface charge.

  • Charging voltage should be 12.8V - 14.7V.

 My power windows don't work!
Please refer to this thread and/or this thread and/or this thread on VWvortex.

 

 Reverse lights do not work
If the fuse/relay and bulbs are okay, replace the reverse (back-up) light switch located on top of the transmission (on automatics, the switch is connected to/near the shift lever).

To test the reverse light switch: Disconnect the electrical plug, jump the black and black/blue wire terminals, turn the ignition switch to the battery-on position. If the lights turn on, the switch is faulty.

 Headlights
Headlamp Type Description
9003/HB2 A 7" round Halogen, dual-filament sealed-beam headlamp with lens optics that came stock on Cabriolets in North America.  These headlamps are usually marked with "DOT" on the lens.  If your Cabriolet has the dual-round set-up, these headlamps are the outer lights and are both hi- and lo-beam.
H3 A 5" headlamp and single-filament bulb assembly that looks like a sealed-beam headlamp ("H3" can also refer to just the bulb).  Once the H3 headlamp assembly is installed, only the H3 bulb requires replacement when burned out. A small variety of wattages, up to 100W, for the H3 bulbs is available.  If your Cabriolet has the dual-round set-up, these headlamps are the inner lights and are hi-beam only (they are not driving lights, nor are they fog lights!).
H4 A 7" headlamp and dual-filament bulb assembly that looks like a sealed-beam headlamp ("H4" can also refer to just the bulb).  The H4 headlamps use the same socket pattern as the 9003/HB2 sealed-beam headlamps and, therefore, are direct replacements to the stock sealed-beam lamps.  Once the H4 headlamp assembly is installed, only the H4 bulb requires replacement when burned out.  These headlamps are usually marked "H4" on the lens. A small variety of wattages, up to 100W, for the H4 bulbs is available.
E-code European-spec (ECE) headlamp.  Stock-type lamp has lens optics; other E-code lamps, listed below, usually are without lens optics.  Has a slightly different (and better) beam pattern than a U.S.-spec (DOT) headlamp and are identified by the "E" logo on the lens.  E-codes are actually not street-legal in the USA, but can be bought from suppliers listing the lamps as for "off-road use only".  These lamps usually use the H4 and/or H3 bulb listed above.  These lamps come with a higher initial cost than sealed-beam lamps, and one replacement bulb can cost as much as a pair of sealed-beam lamps.  However, replacing just the bulb is much more convenient, and these lamps can be used with higher wattage bulbs than what sealed-beams produce.
HID HID stands for high-intensity discharge.  Rather than a glowing filament, this type of lamp produces light by an electric spark arcing across a gap inside a Xenon gas-filled capsule.  This type of lamp produces a brighter, truer-white beam of light.  Very expensive type of headlamp that can also cause glare problems for oncoming drivers.
Angel-eye Type of headlamp that produces a halo-effect when illuminated.  Predominantly used as a cosmetic replacement.  Available as both outer (H4) and inner (H3) lamps.  The H4 angel-eye headlamps are also available with cross-hairs.
"City light" "City light" is a European term for a 5-watt parking light found on the front of European cars and is located inside the headlamp housing, or inside the turn signal housing.  The reason for these lights: When parking on the street at night, the right or left (depending on which side of the street the car is parked) "city light" is to be illuminated.  City lights are not required in the USA, but they come in handy if you've eliminated your Cabriolet's stock bumper lights or have swapped your Cabriolet's USA bumpers to "Euro bumpers".
Crystal-clear, smoked, cross-hair, yellow, blue Aftermarket headlamps that have crystal-clear lenses (without lens optics), smoked (tinted) lenses, yellow lenses, blue lenses, and/or with black cross-hairs in the center.  These lamps usually use the H4 and/or H3 bulbs listed above and, aside from a wattage upgrade from the stock sealed-beams, these headlamps are mostly cosmetic replacements and are usually E-code.
Note 1: If you live in a state that requires bi-/annual vehicle inspections (not to be confused with emissions tests!), using headlamps not stamped with "DOT" may result in a failed inspection.

Note 2: If you are upgrading the headlights to higher-powered lamps, you should add relays to the headlight circuit (see below) to get the most out of your new headlights and to prevent overloading the electrical system (higher-powered headlamps = higher current draw).

 City lights

If you are installing city lights on a North American Cabriolet, wire the lights to the stock wiring based on how you want the lights to be used.

 

Stock wiring in the car:

Black = turn signal

Gray = parking/running light

Brown = ground

 

If you're installing Euro bumper lights that include city lights, you'll need to splice the two ground wires together prior to wiring them to the car's brown ground wires. 

 

 Headlight relays

Whether you are upgrading your headlights or not, it is a very wise idea to relay the headlights.  The stock headlight wiring uses paltry 16 gauge wires, uses the headlight switch as a power source, and contains lengthy wire runs, all of which cause resistance and, ultimately, voltage drop at the headlights thereby reducing each lamp's luminosity.  Adding relays powers the headlights directly from the battery/alternator, will reduce voltage drop in the electrical system, will extend the life of the alternator and headlight switch, will increase the light output giving you whiter & brighter light, and will reduce the chances of the headlight switch overheating.  Click here for a DIY guide for relaying your headlights.  If you'd rather not do it yourself, a complete relay wiring harness is available for approximately $90 at Concept1 , or for $35 at 4Crawler.

 

Before Relaying The Headlights

After Relaying The Headlights

IMG_0443.jpg picture by jettncab

Lo-beam, 10.86 volts at the headlight

IMG_0465.jpg picture by jettncab

Lo-beam, 13.36 volts at the headlight

A standard Halogen sealed-beam headlamp produces 100% of its light output at 12.8 volts (or 13.2 volts in Europe).  Using the "before" image above and voltage drop figures found on the Web, each of those headlamps is producing less than 53% of their possible light output at 10.86 volts.  Pathetic! After installing the headlight relays, each Halogen sealed-beam headlamp in the "after" image above is producing 100% of its light output at 13.36 volts.  Woo-hoo!
Further information regarding headlight wiring, voltage drop, adding relays, etc. can be found at Vintage Watercooleds and Daniel Stern Lighting.
 Headlight switches

Two different headlight switches were used in Cabriolets.  If you're replacing the switch, use the table below to ensure you're buying the correct one!  For example, AutohausAZ lists the 321-K switch for a 1990 Cabriolet, which is the wrong one!

 

VIN

Part Number

Switch

Up to K-009000

(1981 up to mid-'89)

321 941 531 K

From K-009001

(from mid-'89 to 1993)

323 941 531 G
 Installing LEDs

Want to brighten up your lights, or change their color, or reduce the power drain?  Replace the original bulbs with LEDs.  LEDs have come a long way in the last several years.  Rather than buying LEDs and the appropriate resistors, you can now buy LEDs that include resistors for a plug-and-play application in most instances.  Download the DIY Guide for a how-to.  The following is a breakdown of what you need:

 

Bulb Stock Bulb Number* Type LED Replacement Number** Plug & Play LED? Quantity Needed
Instrument cluster PC74 -- B8.3D Yes 3
Gauge cluster PC74 -- B8.3D Yes and No 3
HVAC control -- No 1
Headlight switch, up to mid-'89 2721 Sub-mini wedge 24 Yes 1
Dash switches -- No Varies per car
Courtesy light 211/6411 Festoon 4410-x__ Yes 1
Trunk light 211/6411 Festoon 4410-x__ Yes 1
License plate light 1816/3893 Bayonet, BA9S BA9S (12 volt) Yes 2
Reverse light 1073/7506 Bayonet, BA15S 1156 Yes 2
Tail light 67/5007 Bayonet, BA15S 67 Yes 2
Brake light 1073/7506 Bayonet, BA15S 1156 Yes 2
Brake light - trunk lid 168 Sub-mini wedge 24 Yes 3
Turn signal - rear 1073/7506 Bayonet, BA15S 1156 Yes 2
Turn signal - front 1034/7528 Bayonet, BAY15D n/a n/a 2
Side marker light 1816/3893 Bayonet, BA9S BA9S Yes 4

* The original bulb number is on the left, the current/supersede number is on the right.

** LED numbers are based on www.superbrightleds.com part numbers; this is one of the best sources for LEDs.  Any number listed with "x__" indicates that you can choose how many LEDs come in the bulb.

 

General rule of thumb when it comes to LEDs: Replace the incandescent bulbs with LEDs of the same color as the lens.  In other words, front side-marker light will require an amber LED; rear tail lights will require red LEDs; instrument cluster will require green LEDs if you plan to keep the green hue.

 

LED FAQs:

Q: Can the dash LEDs be dimmed?  A: Yes.

Q: Can LEDs be used in the turn signals?  A: Rear: Yes, but you'll need to wire in resistors due to the lights being wired into the hazard light switch.  Front: Not unless you have Euro bumpers or headlights with "city lights". The North American bumpers use dual-filament bulbs.

Q: Can LEDs be used for the tail lights and brake lights?  A: Yes.  But you'll want to buy red LEDs; white LEDs will wash the color out.

Q: Which ones are better, regular or super-brights?  A: It's up to you.  Generally speaking, if you're using colors other than white, you'll probably want super-brights; if you're using white, go with regular.  However, it all depends on how bright you want your lights to be.  For safety reasons, you don't want your tail lights to be as bright or brighter than your brake lights.

Q: What do I need to do in order to change the interior color?  A: You'll need to buy your preferred color LEDs and remove the green film for the clock and tach/speedometer.  If you like the green hue but just want the lights brighter, get green (yes, green not white) LEDs and leave the green film in the cluster (or remove the film, your choice, but get the green LEDs).

Q: Can I install LEDs into the switches so they match?  A: Yes. You'll need to add a resistor to each switch light, however.

Q: How can I be sure the LEDs work before reassembling everything?  A: With the LEDs installed, apply power to them using a 9V battery.  If they don't work, reverse their positions (polarity matters with LEDs).

 Disabling day-time running lights

Canadian Cabriolets built from 1990-1993 have hard-wired day-time running lights (DRLs) from the factory, as Canadian law requires DRLs.  If, for whatever reason, you want/need to disable the factory DRL system, locate the yellow 20-gauge wire on the back of the headlight switch (it should be plugged into the TFL pin); either push/pull it out of the harness connector, or cut it and cap/tape it off.  You can also disconnect the same yellow 20-gauge wire from the A-21 pin on the back of the relay panel.

 

 Engine sensors, senders and switches
Oil sensors/senders/switches

Part Number

Function Location

Oil temperature gauge sender -- nail-head connector

049919563A

Sends oil temp to gauge Top of oil filter flange
Oil pressure switch (0.3 bar) & gauge sender

035919561

Warns, with a flashing light, when oil pressure falls to near zero and sends pressure reading to center console bar gauge Left side of cylinder head*
Oil pressure switch (1.8 bar) -- 1 pin, white

056919081E

Warns, with flashing light and buzzer, when oil pressure falls too low at higher (2000+) rpm Top of oil filter flange*
Coolant sensors/senders/switches

Part Number

Function Location

Cooling fan thermo switch -- 95-84°C, single-speed fan

Cooling fan thermo switch-- 95-84°C/102-91°C, two-speed fan

191959481B (2-pin)

191959481C (3-pin)

Switches the cooling fan on/off Lower, left corner of radiator
OXS/Lambda probe thermo switch (cold-running enrichment switch) -- round, two-pin connector

035919369D (25°C)

027919369B (45°C)

Controls operation of OXS system (CIS) Underside of upper radiator hose flange on cylinder head (CIS)
Thermostat (87°C)

056121113D

Controls coolant flow Water pump housing inside the lower radiator hose flange
Thermo-time switch -- brown two-pin connector

043906163A

Controls operation of cold-start valve when engine is cold (CIS)

Top of upper radiator hose flange on cylinder head (CIS)

Coolant temp sensor -- blue connector

025906041A

Provides an engine temp input to the Digifant control unit that is used to boost fuel delivery to improve cold-running driveability (Digifant)

Coolant flange on cylinder head (Digifant)

Coolant temp gauge sender -- black connector

251919501D

Sends coolant temperature to dash gauge and warning system (Digifant) Coolant flange on cylinder head (Digifant)

Coolant temp gauge sender -- single, nail-head connector

Coolant temp gauge sender -- white two-pin connector

049919501

Sends coolant temperature to dash gauge and warning system (CIS) Top of upper radiator hose flange on cylinder head (CIS)
Coolant level sensor

251919372A

Senses level in coolant expansion tank; when the level is too low, the sensor sends a signal to the idiot light in the dash cluster (Digifant) On coolant expansion tank (Digifant)
Misc. sensors/senders/switches

Part Number

Function Location
Back-up light switch & up-shift indicator -- manual trans

191919823

Turns back-up lights on when transmission is put into reverse; disables up-shift system when in 5th or reverse gears On top of transmission bell housing
Back-up light switch -- manual trans (1990+)

020945415A

Turns back-up lights on when transmission is put into reverse On top of transmission bell housing
Back-up light switch -- auto trans

 

Turns back-up lights on when transmission is put into reverse Base of shift lever in passenger compartment
Up-shift indicator vacuum switch -- manual trans

171919825B

Relays engine load to the up-shift control unit Connected to vacuum line to/from distributor
Cold-running enrichment vacuum switch -- 1987-1989

171919825B

Interrupts cold-running enrichment above idle (CIS) At front of intake manifold off of the vacuum line going to brake master cylinder (CIS)

Cooling fan after-run thermo switch

191919521B (CIS, blue)

191919521D (Digi, yellow)

Controls operation of 2-stage cooling fan after-run system (1988+) Behind cylinder head cover between #2 and #3 cylinders (1988+)
Cruise control switch -- brake

811907343B

Turns off cruise control system when brake pedal is pressed Above brake pedal
Idle switch

 

CIS: Signals control unit when throttle is fully closed for idle air stabilizer control and deceleration fuel shut-off

Digifant: Signals Digifant control unit when throttle valve is fully closed at idle

On throttle body connected to the full-throttle switch
Full-throttle switch

 

Signals control unit with a signal when the throttle valve is fully open for full-throttle enrichment On throttle body (Digifant) (CIS)
Mechanical air flow sensor -- CIS only

 

Measures intake air flow which then operates the control plunger in the fuel distributor for the proper metering of fuel Under rubber boot on air filter housing, next to the fuel distributor
Electronic air flow sensor -- Digifant only

 

Measures intake air flow; signals from this sensor and the ignition distributor are sent to the ECU for the proper metering of fuel Side of intake air filter housing
Knock sensor -- Digifant only

054905377A

Senses engine knock Front of engine block
Oxygen sensor (Digifant) (Calif. Digifant) (CIS)

 

Sends signal of combustion efficiency to the ECU for fine-tuning of the air-to-fuel mixture (each fuel injection system processes the signals differently; consult Bentley Manual for further info) Back side of engine, mounted in exhaust manifold

*Bentley Service Manual has this gauge's location listed incorrectly

 Rev limiters

The CIS Cabriolets have a rev limiter built into the fuel pump relay.  When the rpm's reach 6500 or so (for a 1.8L; lower displacement engines will have slightly lower limits - see below), the fuel pump relay shuts off the fuel pumps.  This is a safety feature; however, the relay can be replaced with part #321 906 059 F so that the cut-off point is increased to 7500-8000 rpm's.  It is highly unwise to bypass this feature by installing a horn relay in place of the fuel pump relay or rewiring the fuel pump relay because when the key is turned to the "battery-on" position, the pumps will run continuously, even in the event of an accident which could be cause for a very dangerous, if not fatal, situation.  Digifant Cabriolets have a rev limiter built into the ECU and cannot be altered.

 

Approximate rev limits:

1.6L: 6000

1.7L: 6200

1.8L: 6500

 Electrical terminal contact numbers
Ignition Electric Motors
Contact Meaning Contact Meaning
1 coil, distributor (low voltage) 32 return
1a, 1b distributor with two separate circuits (low voltage) 33 main terminal (swap of 32 and 33 is possible)
2 breaker points 33a limit
4 coil, distributor (high voltage) 33b field
4a, 4b distributor with two separate circuits (high voltage) 33f 2. slow rpm
7 terminal on ballast resistor to distributor 33g 3. slow rpm
15 battery+ from ignition switch 33h 4. slow rpm
15a from starter motor to coil 33L rotation left
Battery 33R rotation right
Contact Meaning Wipers/Washers
15 battery+ through ignition switch Contact Meaning
30 from battery+ direct (to component) 53 wiper motor + in
31 return to battery- or direct to ground 53a limit stop+
31a return to battery- 12/24 V relay 53b limit stop field
31b return to battery- or ground through switch 53c washer pump
31c return to battery- 12/24 V relay 53e stop field
31c return to battery- 12/24 V relay 53i wiper motor with permanent magnet, third brush for high speed
Relay Contacts AC Generator
Contact Meaning Contact Meaning
87 common contact 51 DC at rectifiers
87a normally closed contact 51e as 51, with choke coil
87b normally open contact 59 AC out, rectifier in, light switch
88 common contact 2 59a charge, rotor out
88a normally closed contact 2 64 generator control light
88b normally open contact 2    
Turn Indicators Alternator & Voltage Regulator
Contact Meaning Contact Meaning
49 flasher unit in 61 charge control light
49a flasher unit out, indicator switch in B+ Battery +
49b out 2. flasher circuit B- Battery -
49c out 3. flasher circuit D+ Dynamo +
C 1st flasher indicator light D- Dynamo -
C2 2nd flasher indicator light DF Dynamo field
C3 3rd flasher indicator light DF1 Dynamo field 1
L indicator lights left DF2 Dynamo field 2
R indicator lights right U, V, W AC three phase terminals
L54 lights out, left    
R54 lights out, right    
Lights Switches
Contact Meaning Contact Meaning
54 brake lights 81 opener
55 fog light 81a 1 out
56 spot light 81b 2 out
56a headlight high beam and indicator light 82 lock in
56b low beam 82a 1st out
56d signal flash 82b 2nd out
57 parking lights 82z 1st in
57a parking lights 82y 2nd in
57L parking lights left 83 multi position switch, in
57R parking lights right 83a out position 1
58 license plate lights, instrument panel 83b out position 2
58d panel light dimmer Relay
  Contact Meaning
    85 relay coil -
    86 relay coil +
    Other
    Contact Meaning
    75 Radio, cigarette lighter
       
 Wire size conversions
Metric Size American Wire Gauge (AWG) Size General wire size guidelines
0.35 22 16 gauge: 10 amps max
14 gauge: 15 amps
12 gauge: 20 amps
10 gauge: 30 amps
8 gauge: 40 amps

If your runs are going to be longer than about 30 feet of total wire length, bump up to the next size wire to reduce voltage drop on a 12V system.
0.5 20
0.75 18
1.0 16
1.5 14
2.5 12
4.0 10
6.0 8
16.0 4
25.0 2

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The Fine Print


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