The Rat's Nest - 81 X1/9 Build

[Clatter]

Here’s one with the relays lifted up so you can see under it.

Mind blower...!
Those plastic clips at the back of the fuse box hold the connectors!!

Swear to Allah that the PO moved those.
He had bundles of wires in those clips.
I -surely- would have noticed that they were designed to hold connectors!
(at least i'd like to think i would've... ).
No wonder the wiring was all bound up tight!

This brings it all together...
Next wiring session will be WAY different.

Takes a village.
Rodger, send me a bill!

 

[Rod Midkiff]

Something I do on my x1/9's is put an override switch for the fan relay (twofold). One, if the heat switch fails, I can still get the fan on. Two, if I know the car might get hot waiting at a light or on a hot day, I can run the fan before the water gets any hotter.

I also use the seat belt light to indicate the fan is on.

Both changes are easy and only need wires run to the fuse box and a little change on the instrument cluster

 

[Clatter]

Now that wiring is coming front/center into my "life"...

Here's a tidbit from VW world.
Late buses, Vanagons and Porsche 914s use the same L-Jet as the X.
Like the X, they deal with a lot of compartment heat,
Making the harness dry and brittle.
L-Jet woes can be task enough without chasing a bad harness.

In Porsche 914 world, the harness guy is Jeff Bowlsby.
In Bus world it's Kyle.
https://kyleautomotivespecialties.com/

Here's one of his remanufactured Bus harnesses on the right, next to the OG harness from my Fiat on left.
This Kyle harness is about ten years old and has performed flawlessly.
Note the braided wire covering with shrink-wrapped ends.

Terminal wires at the double relay are all labeled.

Later Bosch harnesses used these terminals that push to release, at right,
Vs. the early ones you just yank out.
They hold more securely, and are less likely to suffer damage upon removal.

Here on my X harness, biggest damage is rat chew area at a join.
That, or careless mechanic yankage?

Here's some electrical tape and a later connector.
Score! Er, wait... Um…

Something like this ground barely crimped is easily fixed,
But is the wire still going to be long enough?

So, to do this correctly and fix the EFI on my Fiat once and for all,
The harness would get shipped off to Kyle.
With AFMs, TTSs, IACs, CHTs etc. being increasingly rare, problematic, and expensive,
The last thing you want is wiring trouble.
Years ago, when Kyle did my harness, all he needed was the computer and AFM plugs as cores.
Cut them off an old harness and mail in an envelope…
He had everything else to make what's essentially a new harness.
With the X I'm guessing he never did one, so you'd have to send the whole thing.
It's a few hunnert bux.

Like many Fiat owners,
My car isn't worth fixing correctly.
Gonna have a go at patching it up.
We'll see what happens.

Want to do it right and proper,
Nice to know there's the option.

 

[Clatter]

Something I do on my x1/9's is put an override switch for the fan relay (twofold). One, if the heat switch fails, I can still get the fan on. Two, if I know the car might get hot waiting at a light or on a hot day, I can run the fan before the water gets any hotter.

I also use the seat belt light to indicate the fan is on.

Both changes are easy and only need wires run to the fuse box and a little change on the instrument cluster

Hot tip.. Thanks for the info.

Plenty of good tricks to be done no doubt.

Wanted to remove the seatbelt interlock stuff,
(there's a no-start just waiting to happen)
The 'stupid box' that warns when it's time to change the O2 sensor,
Power window or A/C stuff,
Make more room for things that actually get used.

Then, maybe bigger main hot and grounds?
A big lug to pull power for relays and to replace the multi-wire battery+ terminal?

Whoo! Rabbit hole!

At this point i first need to get back to zero.

 

[Mark_Toro]

"Later Bosch harnesses used these terminals that you push down on the wire to release, at right,
Vs. the early ones you just yank out."

Wait, you mean your just supposed to yank them off? How many hours I wasted trying to push the end of the wire retainer with a little screwdriver!

Actually, I've gotten good enough now to be able to do the old style with my fingers. Kinda catch the end of the wire in the meat of your fingertip and push it out of the way while pulling. Ugh - been messing with this junk too long.

 

[Rupunzell]

Wanted to remove the seatbelt interlock stuff,
(there's a no-start just waiting to happen)
The 'stupid box' that warns when it's time to change the O2 sensor,

There is no seat belt interlock on later EFI exxes.. only early US of A cars had this to meet DOT requirements from that era.

There is no "stupid box" for the O2 sensor on the Bosch L-jetronic injection. If the O2 sensor is dead, there is no indicator.


Bernice

 

[ng_randolph]

There is no seat belt interlock on later EFI exxes.. only early US of A cars had this to meet DOT requirements from that era.

There is no "stupid box" for the O2 sensor on the Bosch L-jetronic injection. If the O2 sensor is dead, there is no indicator.


Bernice

There is no actual checking of the O₂ sensor, but there is the 30k mile counter box that turns on the "Check Ox Sensor" light. And the box can be removed with no ill effects.

 

[Alex(Tenerife)]

So, to do this correctly and fix the EFI on my Fiat once and for all,
The harness would get shipped off to Kyle.
With AFMs, TTSs, IACs, CHTs etc. being increasingly rare, problematic, and expensive,
The last thing you want is to be chasing wiring trouble.
Years ago, when Kyle did my harness, all he needed was the computer and AFM plugs as cores.
Cut them off an old harness and mail in an envelope.
He had everything else to make what's essentially a new harness.
With the X I'm guessing he never did one, so you'd have to send the whole thing.
It's a few hunnert bux.

Like many Fiat owners,
My car isn't worth fixing correctly,
So I'm gonna have a go at patching it up.
We'll see what happens.

Want to do it right and proper,
Nice to know there's the option.

I did something similar not so long ago. I did mine in situ tho.
What I did was remove all the insulation. Carefully checked where each wire went. Did this by disconnecting everything so I could use multi meter to check connections. Drew out the wiring diagram and then, wire by wire, changed them for new. Pop the wire out of the ECU, traced where it went. Removed it on the other side, then replaced it with new.

To be honest I left the earth as mine was pretty good condition as was the main power that went from ECU, relay, injectors. I think I spliced in from good to the injector loop.

All finished off with new heat shrink and new plugs where available and new pins in the ECU.

This was what I called a loom refresh or partial rebuild/tidy up (I was adapting the harness from uno turbo to fit X 1/9 so the lengths where wrong in many placed.

Not too hard too rebuild and refresh but be methodical.

Probably cost me about £100 in parts and tools but I also bought far too much wire so if I knew what I needed would have been cheaper.

Very satisfying to do.

Don't know if this help any, but hope it does.

 

[Clatter]

Little brother helped today.
Up at 4AM for work, but that meant he was home by 9!
He also was super sore from a session at the climbing gym last night.
Not my problem!!

I repent...!
Was saying how stupid it was that Fiat used bolts into soft case material.
It wasn't Fiat!
I followed a stupid PO doing stupid PO things.

Got studs glued in all three of those now.
We'll see if it holds oil tomorrow after the pookie sets up.

 

[Clatter]

I did something similar not so long ago. I did mine in situ tho.
What I did was remove all the insulation. Carefully checked where each wire went. Did this by disconnecting everything so I could use multi meter to check connections. Drew out the wiring diagram and then, wire by wire, changed them for new. Pop the wire out of the ECU, traced where it went. Removed it on the other side, then replaced it with new.

To be honest I left the earth as mine was pretty good condition as was the main power that went from ECU, relay, injectors. I think I spliced in from good to the injector loop.

All finished off with new heat shrink and new plugs where available and new pins in the ECU.

This was what I called a loom refresh or partial rebuild/tidy up (I was adapting the harness from uno turbo to fit X 1/9 so the lengths where wrong in many placed.

Not too hard too rebuild and refresh but be methodical.

Probably cost me about £100 in parts and tools but I also bought far too much wire so if I knew what I needed would have been cheaper.

Very satisfying to do.

Don't know if this help any, but hope it does.

Ya, this is what I'm going to attempt,
Only the 'lite' version.
A few repairs and away we -should- go...

 

[Clatter]

There is no seat belt interlock on later EFI exxes.. only early US of A cars had this to meet DOT requirements from that era.

There is no "stupid box" for the O2 sensor on the Bosch L-jetronic injection. If the O2 sensor is dead, there is no indicator.


Bernice

This is mis-labeled??
You sure?

 

[Clatter]

"Later Bosch harnesses used these terminals that you push down on the wire to release, at right,
Vs. the early ones you just yank out."

Wait, you mean your just supposed to yank them off? How many hours I wasted trying to push the end of the wire retainer with a little screwdriver!

Actually, I've gotten good enough now to be able to do the old style with my fingers. Kinda catch the end of the wire in the meat of your fingertip and push it out of the way while pulling. Ugh - been messing with this junk too long.

Ya, those old style are supposed to just yank out...
At least grab the plastic connector and not the wire!

Trying to pry that little wire loose with a tiny screwdriver?
You'll drive yourself nuts!

 

[Clatter]

There is no actual checking of the O₂ sensor, but there is the 30k mile counter box that turns on the "Check Ox Sensor" light. And the box can be removed with no ill effects.

That box is -exactly- the kind of thing that makes me very happy to throw as far as i can...

Thanks for confirming vestiges won't harm.

 

[Clatter]

Had a couple more sessions with fusebox.
Can only do a few hours at a stretch before the old body starts protesting.
Thanks to Rodger's pics it's starting to seem possible.
My spontaneously bursting into tears doesn't seem as likely anymore.

From looking very closely at pics, and also the two wiring harnesses i have here,
It seems that a certain amount of artistic license was given to the guys who install these.
No two appear to be the same.
Because it's a super-tight fit, and my wires had already taken a 'set', it seems important to get them all back like they were.
Or at least as close to 'like they were' as i can...
Don't want any undue strain on 40-year-old brittle wires and connectors.

Here's how it's ended up so far.
Hard to tell which bundles, if any, go through that top plastic clip.

It can indeed all be smashed up into position at this point.
Takes a scary amount of upward pressure!
Straining, straining, the fasteners do not pop free(!)
At least sitting here still in the drive...
Pretty sure this is how it's to route.
Nice to see it tucked into clips and tidy again.
Not sure if the rear harness is to go through that top set of metal clips.
No other pics of other cars i found show that top pair.

Keeping the wires from escaping the right side of the box and getting pinched to the body.
Tucked into place like this definitely helps.

Another run-through with pictures and maybe another check and tuck session,
And I'm thinking we have it.
Working outward from here, seems almost pretty straightforward.
Touching wood...

 

[Clatter]

Man... Hope springs eternal!

Those pellet things sure -look- like something rats would pack away, don't they?

Especially when you mix them with sunflower seed shells...

Hm.
Wonder if this was dealer-installed,
Or maybe a replacement?

Have to ruminate on what to do with this now...
Muffler seems high quality and in really good shape.
Might just give it my best try to gouge the remaining pellets out of the cat?
Pretty sure a fresh well-tuned motor will smog without the full complement of cat pellets.
Then there's also the adventure of trying to clean them all out of the muffler.
As you know, the way mufflers are designed, things get trapped.
Especially large heavy metal pellets...
They rattle around in there loudly.
It's gonna make such a racket!

 

[Clatter]

Slowly been piecing together the compartment.

One at a time, cleaning and installing, trying to figure out how everything goes.
Other than the fat hoses, that's pretty much it.

Got the ignition parts mostly in place.
Once it's all here it seems to make sense what goes where,
Just need to make sure the routing is tidy.
Since there are quite a few wiring repairs needed, and routing determines length...

Once the fuel tank goes in the plumbing all should make sense.
Thinking i got this side mostly sussed...

Right rear corner of compartment has the most mystery.
Does the wiring go into those welded-on metal tabs -
Taking the 'long way around' the compartment..?
Does the big fat alt wire run up over the top of the engine next to the vacuum advance hose?

Really want to make sure this thing goes together 100% like it should for compartment stuff.
Even if the motor has to come back out or whatever (God forbid),
At least these things -should- be able to stay in place for a long time.

-Now- is the time to get this stuff correct because it's supposed to be for good.

 

[kmead]

Later Bosch harnesses used these terminals that push to release, at right,
Vs. the early ones you just yank out.
They hold more securely, and are less likely to suffer damage upon removal.
View attachment 85894

Want to do it right and proper,
Nice to know there's the option.

One doesn’t yank those, one removes the spring clip with a small screwdriver.

Upon doing so, you then try to figure out where you heard the sound where the clip ricocheted to… At least the first one then you learn to cover it with your hand as you remove it.

Great resource you linked to there. Nice work and worth it if your wiring loom is beat by time, heat and critters.

 

[kmead]

That box is -exactly- the kind of thing that makes me very happy to throw as far as i can...

Thanks for confirming vestiges won't harm.

Save the connectors so you can add the two relays to the wiper motor circuits to speed those up a bit.

 

[Clatter]

Out there before 8 and didn't cut out until 6 or so.
Didn't even take a lunch.

SO many little tasks to put a whole car together i won't bore y'all.

Soaking wiper shafts,
Runk inges draining in the lid after they came out.

Got my gift master from Rapunzel back from Karp's.
Thanks again Bernice.
She sent me four, and i sent them all to Karp's.
That way they'll have them in stock as cores if anyone needs one.
A lovely stainless sleeve job, honed to smoothness.
Contact Karp's Power Brake in Chino, CA if you want this:

Using this fine forum for reference.
Comparing the aftermarket stuff.
Looking closely at the seal and rings in the OG master,
They are slightly larger in size, thicker than new aftermarket.
Since they were in good shape, pliable/soft and not nicked,
Against all ordinary sense they got re-used.

Getting down to where many of the nuts/washers needed aren't showing up in the box.
Plenty of them not needed are though!
Here hunting dome light switch mounting screws.
Good thing I've been hoarding metric hardware for, like, ever...

And to finish, something that really sucks.
Reading here somewhere that those tiny 3A fuses were scarce,
I was stoked to have two pair.
Who would have ever guessed that a few hours in an ultrasonic with Simple Green and water would dissolve them!?!?

Most all of these fuses are 16A.
Wiring diagram shows mostly 8s.
Go figure!

 

[Clatter]

OK, so now I’m really confused..

Here I found a pic of another car with the spring loading the throw out bearing:

My car, they had the spring unloading:

What's correct?

Also, dig my tatty speedo cable!
It goes into that clip, right?
Functionally, it works.
Inspected and lubed and we're running it!
They're expensive, relatively easy to change, and non-crucial to the car's ability to procced.
But,
What's that little flat washer thing that showed up?
Anybody know??