Well I've decided to make my own wiring diagram from scratch because the Haynes one has numerous errors (I've told Haynes and they replied that they know!) and because when I'm talking about it I want something that isn't copyright someone else

I'm building it using Adobe Illustrator and using multiple layers so that I can switch things. There will be one layer for the standard dash (top left of the diagram) and one for the TD5 dash so it can switched between the two. Doing this also allows me to do an actual circuit diagram for when I start my threads on building an auxiliary fusebox/relay box and intergrating it with a second battery.

Here's it is with just the power/start/charge section completed and with 300TDi dash nearly finished (which takes up the top 35% ish). I'll be able to print it at A2 with different options which will be great for the garage wall if anyone wants when later. The entire diagram on one page with wiring colours etc is FAR easier for novices to follow, in my opinion.

Oh and I know that there are official ones out there. I can't modify them with alternative dashes/2nd battery options/aux fuse boxes etc.....

Wow, nice work Mr cowasaki you're bloody good at this electrical lark
A big one for the garage wall is also a bloody good idea.

I've just modified it and added a layer for the auxiliary battery.

So here it is with the auxiliary battery layer showing:



and here with the layer hidden (i.e. normal):

I'm going to follow this with great interest, I find vehicle electrics fascinating and intend to build my own loom from scratch including all the extras I want. Is there much difference between 200/300 you?

Discokids said:

I'm going to follow this with great interest, I find vehicle electrics fascinating and intend to build my own loom from scratch including all the extras I want. Is there much difference between 200/300 you?

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300 has an extra fuse box in the engine bay and all use blade fuse boxes. Early 200s used cylinder fuses and not sure when they switched over. I had a supplier for 300TDi fuse boxes for about £8 !! inc crimps so converting them is a good idea.

I'm going to build up my own loom when I re-chassis the car. 8 foot x 6 foot chip board and lay out the old loom on nails with tie wraps. Remove the tape and examine the loom. Then I can remove bits I don't need and attach my existing wiring into the current main loom sections then re-tape it OR just start from scratch.

Am watching with great interest. Fantastic thread. Would love to build a new loom for my 88 110 but wouldnt no where to start. I could buy the colour coded wire easily enough i suppose but the gauge of wire would leave me stumped.

mick the builder said:

Am watching with great interest. Fantastic thread. Would love to build a new loom for my 88 110 but wouldnt no where to start. I could buy the colour coded wire easily enough i suppose but the gauge of wire would leave me stumped.

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Gauges of wire are easy to work out just have a look at my 1st tutorial where I discuss relays and spot lights. Find the maximum continuous power for each gauge of the wire you are using and calculate the maximum power use for that circuit. You need wire at least twice the maximum to be totally safe.