Barn Find Laser Green 1.9 Gti.

[Leslie green 157]

Swapped over the printed circuit board for the back lights in the speedo clocks which was easy enough there are 2 one on top of the other and its the top one . Unfortunately most of the wires had come of the yellow plug which is different from all the rest which have pins , the yellow one the wires splice in like scotch loc connectors and with the clocks being off and on so often have fallen out/ broken off , the black top has to come of which was a rear struggle ,pushed the wires back in , there are 2 reds , i got these the wrong way round it seems and have melted a track in the lower printed board I saw a tiny bit of smoke and got the plugs of immediately but it was too late ,one is 12v + which did the damage I guess . Had tried to look up wire numbers using google but all linked to here and the forum is barely running at all its so slow , looked the haynes too but it didn't tell me any colours but I knew all the colours were right anyway as the pieces of insulation were still in the connector top . The wires to the yellow plug are thinner and  the numbers on them rub of easy and are hard to read and I guess the next number is behind the dash.

 

Good news the back lights on the dash now  all work , but the fuel gauge and main beam light doesn't and I think the oil pressure gauge is not right either . ! step forward 2 sideways , 3 back Lol ! 

[Leslie green 157]

Burn marks along the printed track 

[Leslie green 157]

Had no success measuring voltage as nearly all the pins n the yellow plug have 12v so traced the 2 red wires (there is a circuit between the 2 red wires too) it back to the A Pillar where I  found 30B the oil pressure warning light one  , had to cut the wire to confirm it was the correct one by a continuity test ,, all was going well until I tried to remove the black top of the yellow plug which was loosely fitted or the cables fall out  and snapped it in half , one half went down into the space below the centre vents and has vanished ! Doh  . 

 

If anyone has a yellow Gti plug as they are different I think to non GTI, the Gti one has a black keeper in the top and a piece of loom I could be interested !

[chris 417 mi 61 2 Cars]

i don't have a manual but ... i am trying to get al my dashboard wiring back in ... did you take anymore pics of the routes before dash went in ? 

[Leslie green 157]

I'm not sure how right these are as I had to move stuff later when it wouldn't fit  , most goes over the top of the heater box but the ones for hazard ,fog on that cable go in front of the heater box if that make sense . Get the speedo  plugs in and fitted onto the plastic horseshoe will help locate some wires too. I didn't take many pics when removing and it made it very tricky to put back. If I have to take the lower dash out again to find the broken off bit of that plug I will take some more .

Edited January 7 by Leslie green

[Leslie green 157]

Does the speedo cable go straight down behind the clocks ,there are 2 oval holes where the column first universal joint is once it goes down the round hole in the dash and it can either go left or right though pressed metal  openings on the shell  and no matter what way it seems to follow a bit of a twisted path , if it goes straight down it would be very close to the universal  joint and may catch on it , right is tight to the brake pedal switch .Wish id taken a pic first time I took it apart lol as I don't want to be back in here again ! 

Im talking about the green metal part with 4 studs to hold the column in above pic.

Edited January 30 by Leslie green

[SRDT 231]

Doesn't the 205 has two path for the cable? One central for the low spec dashborad and one on the left for the GTI type dashboard.

[Leslie green 157]

There are 2 holes yes behind the clocks , the left one for gti buts its where it goes behind that im interested in as it goes down the column towards the bulkhead.

Edited January 30 by Leslie green

[bacardincoke 48 1 Cars]

Engine's out at the moment and you can see where the cable exits into the bay quite clearly / may help locate corresponding hole (and the natural path the rigid cable takes) to it from the interior side? (1989 1.9)

 

 

 

 

[Leslie green 157]

Thanks Martin , could you get me a pic in the footwell where it comes out the bulkhead  if possible and into the pressed metal cage  , or even just a look and tell me ,I know its a pain to access ,from your pic it looks like it goes to the right of the column going by the angle which is right by the brake light switch.

[bacardincoke 48 1 Cars]

The interiors still in and like you say it's nigh on impossible to see, let alone take a piccie of things from that side and which'd likely answer your question... sorry.

 

The lower steering column's out and I can reach up in from the engine bay side (where the white cloth's showing in the image).

 

Can't be 100% sure because of that, but the cable does feel to come down through that gap in the side of the pedal box.

 

Having said that, that's also assuming my cable is in correctly.

 

While It doesn't foul as it is, the dash has definitely been out at some point before my ownership. 

 

The yellow line is just an approximation based on what my fingertips are telling me!

 

 

[bacardincoke 48 1 Cars]

Image was filched from the inter-web, so not taken from an ideal angle either...

[Tom Fenton 1,628]

Tricky to photo but hopefully these may help a bit 

The black sleeved thing is the Speedo cable showing how it passes through the cut out 

[Leslie green 157]

Thanks lads as there were LHD to start with I guess they couldn't get a clear path for RHD so it winds a bit, I will look at mine tomorrow but it looks like Tom's goes down and then out the left cutout towards the heaterbox pipes. 

Tom I see the end of your cable is different to mine with 2 tangs on it , mine is a ring type end , these are easy to fit but a right a pain to get off , I see cheap cables with the ball and sleeve but they are LHD ie too short about 900mm . The new one I got has neither the ball nor the slieve but is supposed to be 6123c5 or maybe an oe french manufactured part not genuine  from peugeot parts , I see others about for less than half the price I paid now ! spooks sells a genuine one with the ball in the pic  but its £120 ! No thanks lol !

Going to have to split the ball to fit it on the new cable as I've tried to rejoin the end on the old one but melting the nylon just made a mess.

[Leslie green 157]

After having another think I found a better way to swap the ball of the speedo cable , I levered the end at the speedo off. Clamped the square end with vice grips and levered it off with a screwdriver after giving the hex peaks a squeeze with the vicegrips to loosen its hold, The original only had 2 crimps but the replacement is a hex so not as easy to get off.

Once the ball and sleeve are swapped over fit the end back on after putting the metal crimp on ,push the end on the sleeve  the 10mm or so it slides on the cable then put a bolt in the vice that fits in the centre of the plastic end to give something to push against and tap the metal sleeve on which putting vice grips loosely behind it to spead the force and it will tap on with a hammer against the vice grips and a few taps.

[Leslie green 157]

Pic of refitting , removal one wont upload 

Edited February 3 by Leslie green

[Leslie green 157]

Cable routing , down from dash straight down through upper oval hole then left out the side of the pressing .

Edited February 3 by Leslie green

[Leslie green 157]

Speedo Clocks back in , binnacle plastic 2 recessed mounts on left repaired with fine mesh and Q bond adhesive repair which allows you to make new plastic with powder and superglue glue , close enough its hard to shape and get the angle to the dash right with not much left to go on plus hole re drilled not just right but its on.Every time you take this off another screw mount in bits falls on the ground .The binnacle has a lot of battle scars underneath now lol.

 

Radio and console refitted and another new indicator stalk and cutting the tab of the last new one while refitting the steering wheel.

 

Top tip unscrew indicator stalk  while fitting the steering wheel or the self cancel gets chopped off as you tighten the nut ! 

 

As an unexpected  bonus the digital clock now lights up and even dims when the sidelights are put on which it has never done , dunno why can,t explain it but suspect it was something to do with that yellow plug on the clocks .

 

Anyone know what clips the rear interior black 1/4 panel trims use as those need fitted next ?

 

Edited February 20 by Leslie green

[Leslie green 157]

Disaster while backing  the car back in the shed after getting most jobs sorted , while watching shed door I managed to catch the drivers door on a small lorry body and have mangled it and ripped the mirror off .

Edited March 3 by Leslie green

[Tom Fenton 1,628]

Gutted for you buddy

[Telf 234 2 Cars]

Mate! Rubbish, have been following your build. Its typical. You probably dont remember but my bonnet flew open the wewk after i finished it. 

 

Don't despair as youve learnt everything can be fixed.

[Leslie green 157]

Gutted for sure , place that painted it has closed down too , I only took it out to run it for 5 mins to check the lights etc .

The left indicator icon that was working has stopped again too.

I had just fitted the new reg I got for it  yesterday after watching for one for several years suits it I think.(slam panel is away for painting which is why the grill is off)

Hou can see behind the car is the tesco van storage body I hit , its a right angle in the shed and a tight turn.

 

Paul I remember your bonnet every time I lift a car bonnet and usually check it about 3 times out of paranoia each time im at it.

Edited March 4 by Leslie green

[chris 417 mi 61 2 Cars]

Have you managed to get it sorted ? 

[Leslie green 157]

4 hours ago, chris 417 mi said:

Have you managed to get it sorted ? 

No mate as its currently sorn I haven't bothered, I got a replacement mirror cheap , fitted it and when I went to adjust it the handle came off in my hand ! about the way it goes with this car lol. Its up for test (mot) next week so got the indicator working today , it was a bulb on the back of clocks again  , getting good at removing the binnacle  now though another piece of plastic mounting screw hole falls off each time ! I put an old slam panel on while the other is away for paint as its going to be a while but its rusty at the 2nd catch area so it drags on it and is hard to close . Currently there is no way I can get over the field to get out without putting it on a trailer as its so mucky.

 

I actually have a door but there looks like rust in the bottom but it may be just off the runner that was rotten as otherwise it looks good only a couple of small dents,I will drill the kit holes and strip it first.  There is a local bodyshop I may try for a quote but a paintless dent job would make it look a lot better as matching this colour will probably need a side painting and I don't want it offroad all summer.

Edited March 25 by Leslie green

[chris 417 mi 61 2 Cars]

Ah that's a shame, sounds like a gravel path is needed ! 

Tbh the guy who painted my laser did a very good job matching the paint, it might not be as bad as you think  don't let it sit otherwise you will be looking at it in 2-3 years time the way life seems to go atm !