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After completing a pretty good round of tearing apart the dashboard, I've got a new problem and a couple of observations.
First of all, the main problem I'm having. Fuse 5 blows. Looks like it's blowing on overload. It's not vaporized, really just melted. I haven't been doing anything unusual when it's blown. One night it blew 3 fuses. The annoying thing is of course, I lose turn signals and that pisses off the other drivers. I hate not being able to signal.
Fuse 5 is described on the cover as powering:
Direction Indicator
Tail Lamp (?)
Control Unit Preheater
Diesel
Power/Heated Rear Mirrors
OK, so I don't have power or heated mirrors. I wrote down the tag as it's written- I'm kind of assuming the "Control Unit Preheater Diesel" is a glow plug relay. If, on a gas engine, this is the heater for the O2 sensor, I'd understand that as well. Coincidentally we have a 94 Golf hanging around- it's latest trick was to blow the fuel pump fuse. Turns out the O2 sensor grounded on the trans tunnel, and blew the "Control Unit Preheater" circuit which also took out the fuel pump fuse. SImple but maddening.
Anyway my turn signal relay looks ok, and clicks fine when working. It's not melted, as I have seen happen.
Looks like just 2 blue wires off this fuse, and I've got Bentley's here, going thru it to track down all the circuits.
Now the monkey wrench: I've just had this whole damn dashboard apart. I installed my JVC Cd changer in the trunk and the head unit in the dash. I removed the factory amp and replaced it with the old style deep change tray out of an 89. I pulled the factory amp plug up to the top and spliced into it to get at all the speaker wires. I borrowed one green power wire from it to run the 12V to the changer. I installed an older style 9-pin plug so my pre-wired stereo would be more plug-n-play. I installed front speaker harnesses from an 89 to replace the cut up ones in the car. (All 8 speaker wires in the car were cut off and spliced close to each door.) I did run an extra wire from the fusebox to the instrument hole for a voltmeter; I've since removed this without any change to the problem. All the stereo wiring works, all 4 speakers work, power to the changer works, the power antenna goes up and down when I turn it on and off, all no problems. I haven't observed any other problems in the harness or fusebox EXCEPT:
1) Fuses all had typical white oxide corrosion on them
2) #6 fuse, 25A to main fuel pump, SMOKIN' HOT. Got to be close to 200°F. It will burn you and leave a blister. Wires to it look ok, connection tabs look OK, fusebox surprisingly is not deformed from the heat. But it's right under the one that's blowing...
3) A little bit of green corrosion between #5 and #6. I cleaned up most of it but I'm sure there's still a bit down in between the tabs.
4) Over the fusebox there is a heavy gauge white/black striped wire with some cuts in it, like an amateur was in there cutting the harness or wire ties- and I know some of that was done.
I will look for other issues- I do know at some point fog lights were added and some other things, and all done by "strip and twist" wiring, not at all a professional job here. Any ideas appreciated... thanks in advance.
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Rob Bareiss, New London CT ::: 92 244-M47-207K ::: 90 745GL-M47-268K ::: 88 245DL-AW70-230K ::: 88 244 SOLD! 87 244 SOLD! Still looking for a bright red or black 244 with sunroof...
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