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Post by Stiffy on Feb 7, 2017 19:00:41 GMT
How to Rewire The Bond Bug If your Bug has never had its wiring loom replaced chances are it may have been bodged over the last 40 years. New looms are available from Dave at the Spares scheme. Before replacing the loom its wise to purchase a new set of plastic clips so you can re clamp it to the body. It’s also worth having electrical fastenings and insulating tape. You can replace the loom with the body off but I replaced mine while it sat on the chassis. To replace the loom start from under the driver seat and feed the two sets of wires up through the holes under the dash cluster. Make sure before you start the loom is the right way up. You will then have a set of wires that head of in the direction of the Dynamo/ Nearside Lights and Horn, 1 set that goes to the Rear lights and another that goes to the Regulator/Off sidelights and Temp-Brake and Oil sender units. Clamp the loom in place along with the starter solenoid (This will need to be connected to the battery with the thick Black heavy duty cable). The next step is to work through connecting each circuit and then testing. Bad earths are a common problem to Bugs so check this area and clean up the crappy connections you will undoubtedly find. When it comes to the lighting circuit, There are numbers on the back of the switch and these relate to different wires - If you look very closely on the wiring diagram in the Hand book you can just about make out where they go. (The Diagram does not show it). I have found if you connect the wires to the fuel gauge in the wrong order the gauge flies up to full - So you may have to experiment until you get the sequence right on this (The green wire goes on the Battery tab). There is a small error in the 1970s Wiring Diagram which I have noted on the diagram below - With regards to the Wiper Motor the Wire shown as Purple and Light Green should be Red and Light Green. Double click Image below for full diagram. 
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Post by ady on Feb 8, 2017 9:14:10 GMT
Chris and me replaced the loom on his Bug. The car was fully assembled and there was little need to dismantle much. The old loom was out and the new one in within a weekend. Everything worked baring the need for a new brake light switch, which we didn't have.
We did have to swap some of the connectors, I think there are probably production differences between some cars. So as Ivan says have a selection of bits available too.
Don't be daunted by the mess of wires that you pull out of the bag when it is delivered. Just lay it out on the floor and spread it out as it is when installed, you soon start to see what connects to what.
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Post by chrispbug on Feb 9, 2017 21:29:14 GMT
I remember that weekend well. Credit where credit is due, Ady did 99% of the work in very trying conditions. Outside and under a tent awning !
We just supplied beer, food and a bed for the night !
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Post by bugdonna on Feb 9, 2018 13:55:21 GMT
Ha, good to know! Thanks. We just keep finding problems with it and toying with the idea of just a complete new loom... Husband is an industrial sparky, so could be for a weekend  |
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Post by mikebentley on Feb 16, 2019 11:40:10 GMT
Hi all
I have bought a complete car that looks like it was in the processes of having the body put back on.
I'm am attempting to get it running and driving before I do a total re-build including a rialto chassis
I have found a bunch of earth wires connected to 1 eye terminal that is behind the speedo once I attached an earth to it from the battery then bingo we had power to start the engine and the headlights work.
The question is were should the eye connector connect to
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Post by ady on Feb 16, 2019 13:35:03 GMT
I have this connected to one of the bell housung bolts. I think this is how they were originally done.
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Post by mikebentley on Feb 16, 2019 13:39:53 GMT
Thanks ady
That's what I was thinking of doing
Its all about good earths on a plastic car
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Post by ayrbugger on Feb 17, 2019 16:34:09 GMT
mikebentley,
earths...they are essential, mine link from a central bolt at the top of engine bay beside fuses then down to engine to battery to rear lights etc etc you can't have enough links.
Keep them all the same colour code and its much easier to check for faults and extend as required.
Bill
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Post by rolydog2001 on Feb 27, 2019 21:31:40 GMT
Any one have any pictures or made any notes about what wires go to what switch? Just trying to wire this up and a lot of the wires in the Autosparks loom don't exactly match up with the above diagram. Likewise any pics of a newly fitted fuse box showing layout and original location would be helpful
Thanks
Chris
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Post by Stiffy on Mar 1, 2019 11:37:39 GMT
The fuse box is located above the starter solanoid to the left of the panel behind the light cluster. All the switches for the heater etc are green as are the wiper etc. If youget stuck feer free to contact.
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Post by rolydog2001 on Mar 1, 2019 21:08:32 GMT
The fuse box is located above the starter solanoid to the left of the panel behind the light cluster. All the switches for the heater etc are green as are the wiper etc. If youget stuck feer free to contact. Any chance of a pic, as I'm not even sure where the starter solenoid is mounted (other than where the wires roughly) end up, Cheers |
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Post by Stiffy on Mar 2, 2019 20:20:00 GMT
i will take a picture unfortunatly Im working till tuesday  |
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Post by Stiffy on Mar 5, 2019 16:45:05 GMT
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Post by rolydog2001 on Mar 5, 2019 19:53:00 GMT
Thanks, I have printed them out and will have another look in the daylight. This is what I posted on Facebook and where my problems lie:
Ok I'm struggling with what should be a relatively simple job of wiring up a bug. I have the Autosparks alternator loom and am re-fitting everything mostly with new components. I did not disassemble this car as it was purchased as a project. Would anyone have re-wired a bug using this loom (a lot of the wiring colours dont match the oe) that could help me out with some either detailed pictures or that I can visit? Thanks
Chris
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Post by rolydog2001 on Mar 28, 2019 19:16:48 GMT
Still stuck on this I'm afraid. Surprisingly Autosparks don't seem to have any reference material as to what wires do what. As wrote the loom does not match the existing (OE) wiring diagram. Ideally I could do with good clear pictures of an autosparks loom behind the switches/speedo and fuse box layout.
Thanks
Chris
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Post by cdb15 on Mar 29, 2019 9:29:28 GMT
Still stuck on this I'm afraid. Surprisingly Autosparks don't seem to have any reference material as to what wires do what. As wrote the loom does not match the existing (OE) wiring diagram. Ideally I could do with good clear pictures of an autosparks loom behind the switches/speedo and fuse box layout. Thanks Chris Given that Autosparks specialise in classic looms, and given that on their web site they claim "Original Manufacturers colour coding is used where possible;" I wonder if the loom you've got is not for a Bug...
Did you actually buy it new from Autosparks? They stress all over their website how they stick as closely as possible to both the OE specifications and the British standard colour coding, so if your loom colours are substantially wrong, it sounds to me highly probable you've got the wrong loom.
Another option is to get a known-good loom from someone who is currently doing a resto and has their loom lying idle at present (hopefully labelled as to each connection!), lay the two looms out on the ground side by side and do a wire-by-wire comparison, labelling as you go. When you return it to the helpful owner, make sure you send him/her the 'correct' loom ... 
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Post by rolydog2001 on Mar 29, 2019 19:12:58 GMT
The loom came from the spares scheme, yes it's fitted all in the correct locations! The only areas I'm having issues with is as wrote above, the fuse box/switches/speedo. As to what wire goes where.
Thanks
Chris
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Post by cdb15 on Apr 1, 2019 19:54:09 GMT
The loom came from the spares scheme, yes it's fitted all in the correct locations! The only areas I'm having issues with is as wrote above, the fuse box/switches/speedo. As to what wire goes where. Thanks Chris In the absence of any other help, all I can suggest then is good old fashioned wire tracing. I don't have a circuit diagram to hand, but you obviously have the original Bug one, so you can use that. If you take one area, say the speedo, the circuit diagram will show you so many wires connected, let's say there are three. If you trace those three wires back on the circuit you'll see each of them arrives at some physical point that you can access. Say, a switch terminal, or an earthing point, etc. Now, let's say you have a total of 20 wires you don't know what to do with. Of those 20, 3 of them should be for the speedo. All you do is stick one circuit tester wire on the physical point you identified - the switch terminal or whatever - and connect the other tester wire to each of your 20 wires in turn. When you get a match that's the wire you need to connect to where the circuit diagram tells you. It's tedious, and you need to test all 20 possible options in case you get a match with more than one (if you do, leave that point for now and move on to another one, and gradually the double positives should get eliminated.) Once you identify which wire goes where, don't forget to mark the actual wire colour code on your circuit diagram for future reference. When you've done the 3 wires for the speedo, then choose another small area, say the light switch. Now you only have 17 wires to test, and so the number of tests for each wire gets less and the task becomes less tedious.
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Post by rolydog2001 on May 25, 2019 18:10:21 GMT
Unfortunately I don't, I purchased a stripped partly restored project car, and having no reference point (along with missing parts) has made it more of a challenge than I thought it would be. I'm disappointed with Autosparks to be honest, no matter what they deny having any wiring plan/layout that they will give out to buyers of one of there products. Unfortunately the new looms don't match the old looms that I have kindly been given pictures of. I have got parts done so have got some wires sorted. Stiify, the picture you posted above is very helpful however I cant make out the wires and colours from some of the switches. could you write it down in a format I could decipher please? Thanks Chris
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Post by Stiffy on May 25, 2019 23:19:27 GMT
Hi chris,
I will take the switch panel of the DNA Bug and write them all down. Dont get bogged down with the whole loom. Just concentrate on one section at a time and dont start another until your happy.
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Post by Stiffy on May 26, 2019 12:27:43 GMT
OK here goes..
Ignition Switch
Number 1 goes to Red
Number 2 goes to White
Number 3 goes to Brown Blue
Lighting swich
Number 1 is Blue /Brown
Number 4 is Red
Number 8 is Blue
Others are redundant
Wiper swich
Green top left
Red green Below it
Brown Light Green next to the red green.
Terminal next to the green is redundant
Heater
Green is the live feed
Out put is Green Yellow
Indicators
Green Live feed to middle terminal
Green White to indicators
Green red to indicators
Swap round if wrong indicators flash
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Post by rolydog2001 on May 26, 2019 19:43:53 GMT
Top stuff, thank you. I wont get to have a look until the weekend, but will let you know if it aligns to what I have. if you happen to have the instruments out as well......... :-)
Chris
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Post by sd1 on May 29, 2019 18:34:36 GMT
Nice one 👍
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Post by rolydog2001 on Aug 1, 2019 19:38:29 GMT
Would any one be able to look at the back of the instruments please and either take some very good and clear shots of the wiring or draw a diagram of what goes where please?
I have sussed most of it I think but need to check a few connections.
My intention is (if and When) I can get this sorted is to do a write up for how to wire up the New Bug Autosparks loom as it varies so much for the original, That way it should help everyone out!
Thank You
Chris |
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Post by mike on May 28, 2020 9:15:02 GMT
Hi there did you get your wiring sorted and draw a diagram. Im in the same position of wanting to know yje wiring at the back of the instruments. Could you help. If you can you can e mail me on micky2@sky.com
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Post by rolydog2001 on May 28, 2020 19:35:02 GMT
Yehh I did do a diagram for the new Autosparks alternator loom, I will see if I can dig it out for you not sure where it is at the moment as I'm trying to juggle stuff whilst looking after my dementia ridden mother. Though I'm sure there are more 'special' ones that can help.
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Post by rogeru7 on May 28, 2020 19:49:58 GMT
Hi there did you get your wiring sorted and draw a diagram. Im in the same position of wanting to know yje wiring at the back of the instruments. Could you help. If you can you can e mail me on micky2@sky.com Hi these my be of help regards roger |
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