The Rat's Nest - 81 X1/9 Build

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!! :oops: :oops: :oops: :oops:

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! 😁
 
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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
 
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.
IMG_8472.jpeg


Terminal wires at the double relay are all labeled.
IMG_8473.jpeg


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.
IMG_8475.jpeg



Here on my X harness, biggest damage is rat chew area at a join.
That, or careless mechanic yankage?
IMG_8477.jpeg


Here's some electrical tape and a later connector.
Score! Er, wait... Um… 🤨
IMG_8478.jpeg



Something like this ground barely crimped is easily fixed,
But is the wire still going to be long enough?
IMG_8479.jpeg



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.
 
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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! :p

At this point i first need to get back to zero. ;)
 
"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.
 
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
 
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.
 
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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.
 
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!! 🤣
IMG_8480.jpeg


IMG_8483.jpeg

IMG_8484.jpeg

IMG_8485.jpeg


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. :rolleyes:

Got studs glued in all three of those now. :cool:
We'll see if it holds oil tomorrow after the pookie sets up.
 
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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... ;)
 
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?
IMG_6276.jpeg


🤣
 
"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! 🤪 🤪
 
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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.
 
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