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Author Topic: Report on (slow) S2 Coupe rebuild progress  (Read 58704 times)
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nthomas1
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Posts: 668



« Reply #600 on: 17 October, 2020, 10:42:19 PM »

David, thanks for your input. The battery only charges to 12 volts so it sounds like it is time to buy a new one. The car is not running yet, so I carry the battery 100 yards to charge it indoors (no power in the garage). It has dropped from 12 to 10.8 volts while Iíve been carrying out electrical checks over the last three days.

I assumed 10.8 volts would be sufficient for testing the headlights, but I guess I was wrong. The wires that carry the current from fuse 7 to  fuses 1 and 3 via the solenoids have been checked and all connectors scrupulously cleaned with wire brush and emery paper.

Iíll do the main beam solenoid test tomorrow and then decide how to move forward. 
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
Various modern cars
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
nthomas1
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Posts: 668



« Reply #601 on: 18 October, 2020, 02:32:58 PM »

I labelled the wires in the fuse panel and removed the fuse rack today, and started working my way through the wires, inspecting each and cleaning the connectors.  So far just one wire looks problematic.  It's been covered in tape which, when removed, reveals three or for breaks in the casing. It will need to be replaced.  Tricky, as it is paired with a very thick red wire that may make it beyond my crimping tool's capability!

Interesting to see the design differences between the fuse rack that I've removed and the cleaned up one that I'm replacing it with.

 


* a wiring.JPG (703.74 KB, 1417x1063 - viewed 3 times.)

* c - Fuse Racks.png (822.79 KB, 1134x593 - viewed 7 times.)
« Last Edit: 18 October, 2020, 03:01:09 PM by nthomas1 » Logged

Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
Various modern cars
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
Jaydub
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Posts: 263


« Reply #602 on: 18 October, 2020, 04:17:50 PM »

Hi Norm,
As you know I`ve been rather busy at Silverstone the last 3 days. so had no input on your problems. As david suggested, get a new battery, fully charged as a good datum point. Also bear in mind what I told you in my PM, having a reading of 12 volts doesn`t necessarily mean it will carry the load. You need a working headlamp, or something similar, to check the load carrying capacity of the various circuits.
Have you earthed the green wire at the White connector block from the lighting stalk? That will bypass the stalk contacts we talked about, in case they are not closing when you pull the stalk towards you.

Let me know tomorrow as I have a day at home.

Cheers John
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1600 HF. S2.
nthomas1
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Posts: 668



« Reply #603 on: 19 October, 2020, 07:00:13 PM »

Thanks John.  I'll try that green wire earthing test as soon as I have the new fuse rack installed and everything connected up.
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
Various modern cars
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
nthomas1
Rebel Poster
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Posts: 668



« Reply #604 on: 20 October, 2020, 05:48:46 PM »


I cleaned all the connectors in the fuse panel today.  I found the best approach to be a wire brush, followed by sanding the inner surface with a thin strip of emery paper - using a needle file to slide it backwards and forwards.  I then applied heat-shrink tubing, and I replaced the one damaged cable that I'd found.   I cleaned up and painted the angled plate that holds the solenoid cluster and then reconnected everything.

I decided to refit the original sidelight solenoid having carefully bench tested it.  I can always change over to the CEAM unit if necessary, but the original unit makes testing easier as all connectors are on the front face and are relatively easily accessible.

I can restart the testing of the lighting circuits tomorrow in the knowledge that that all wires are sound and all connectors thoroughly cleaned.   


* a Cleaning connectors.JPG (767.78 KB, 2126x1167 - viewed 5 times.)

* b Solenoid cluster.JPG (945.91 KB, 1559x1250 - viewed 5 times.)

* d Reconnected.JPG (782.13 KB, 1701x1276 - viewed 6 times.)
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
Various modern cars
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
simonandjuliet
Permanent resident
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Posts: 2194



« Reply #605 on: 20 October, 2020, 06:33:42 PM »

You won't regret the efforts made cleaning connections .... that and proper earths make a huge difference

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S1 Aprilia Cabrio, S2 Aprilia, S1 Promiscuo,S2 camioncino, S2 furgoncino, , R4 Sinpar, R4 Rodeo, R60 Tractor,R60 S, Moto Guzzi Ercole, Disco 3, Mini ALL4 JCW, Moto Guzzi Cardellino 73,Fulvia Berlina GT, Fulvia Rallye S, Royal Enfield Himalayan
Jaydub
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Posts: 263


« Reply #606 on: 20 October, 2020, 07:13:50 PM »

That looks brilliant Norm, very neat and lovely clean connections.
Good luck with the testing tomorrow.
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1600 HF. S2.
Neil
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Posts: 972



« Reply #607 on: 20 October, 2020, 07:40:51 PM »

Norm, very neat a job I never quite finished to get my up and running in 2013, one day I must tidy the wires in the fuse box, I am sure it will all work brilliantly now.
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Neil   
386

1973 Fulvia S2 1.3
Keithver
Member
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Posts: 19



« Reply #608 on: 21 October, 2020, 09:45:11 AM »

Hi Norm. I don't know where I found this originally, but came across it in my filing system this morning. You are probably beyond this, but here it is anyway (attached Below). Hope there is something useful in it
Keith

* Lancia Fulvia Wiring Notes S2 v2.pdf (526.93 KB - downloaded 36 times.)
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nthomas1
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Posts: 668



« Reply #609 on: 21 October, 2020, 12:03:09 PM »


Thanks Keith - I do already have that document, and have found it very useful.
Cheers, Norm
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
Various modern cars
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
peteracs
Administrator
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Posts: 715



« Reply #610 on: 23 October, 2020, 10:07:27 PM »

Hi Norm

If you still have connection problems, it may be the actual crimp connections which will need the connector replacing. I tend to tin the wire with solder, crimp the connector onto it and then solder the wire to the connector. A bit belt and braces, but makes sure the connection is good with the wire.

Peter
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Beta Spyder S2 pre F/L 1600
Saab 9-3 1.9Tid Cabrio
nthomas1
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Posts: 668



« Reply #611 on: 24 October, 2020, 03:32:29 PM »

Thanks for the advice Peter. Soldering is not a skill that I have, but I've got the equipment so must teach myself.
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Norm Thomas
Ormskirk, Lancashire

Own:
1973 Fulvia S2 Coupe
Various modern cars
Previous Lancias: S2 Coupe and S3 Coupe in late 1970s
davidwheeler
Permanent resident
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Posts: 1137



« Reply #612 on: 24 October, 2020, 10:00:57 PM »

It is not difficult.  Make sure everything is clean, you have flux cored solder and, most important of all, that you get things hot enough, I suggest a Weller 40 watt iron for small jobs like this.   The solder should flow freely.
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David Wheeler.  Lambdas, Aprilia, Fulvia Sport.(formerly Appia and Thema as well).
Jaydub
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Posts: 263


« Reply #613 on: Yesterday at 09:44:35 AM »

Ref. soldering Norm, on some of the older wiring make sure you remove the verdigris that builds up sometimes, get the wire clean and shiny.  Also when soldering terminals to cable, heat the terminal NOT the cable.

Good Luck.
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1600 HF. S2.
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