I have tried to write this article with the aircooled VW in mind, but as I
have not written anything too specific to the VW you could apply it any car.
Let's start with a look at the way the electrics work on your
car. You have a battery to store the current, a generator to
replenish it and an ignition switch to provide power to a
majority of the car only when you are there or when the engine
is running.
When the ignition is off there are some areas of the car that
still require the power of the battery, namely the interior
lights, the parking lights and the radio memory or in some cases
the whole radio. That is only a short list, but there really
isn't too much else on a non computer controller car that
requires any power.
When you switch on the ignition you then begin to power many
more parts of the car even without you intentionally switching
them on. For instance the lights that come on on the dash
display, those are the oil and generator warning lights, the oil
light is switched on when the engine oil pressure drops below
about 6psi (1/2 bar) and obviously when the engine isn't running
it will light up as the pressure is 0 psi. This enables us to
use this as a bulb test. If the light doesn't come on then the
bulb doesn't work or there may be another problem, but we'll
stick with the basics at this point. Also the generator light
comes on, this is a voltage comparison between the battery and
the generator output, so if the fan belt breaks the voltage
output of the generator will be less than the battery and the
light will come on and with the engine not running the light is
obviously going to light. If this doesn't happen, then you may
have either a bulb blown or another fault.
If either if these lights fail to light with the ignition then
look into it now not later. Imagine the bulb for the oil
pressure warning had blown and you drove off without changing it
and whilst on the road your sump nut came loose and all the oil
poured out your engine would seize up and the first thing you
would know about it was a loud bang.
A common statement I have heard over the years is "The car won't
start the battery must be flat" when in fact it's a problem with
the engine not the battery. If the starter motor turns the
engine over then the battery is working fine. If the engine
will not turn over at all, turn something else on, a radio or
the winscreen wipers and if they work then the battery is not
the fault. Trying simple tests like this could save you looking
a fool in front of the recovery guy and maybe any call out
charge.
If you decide to recharge the battery, remember to do out of the
car and not in. When you remove the battery disconnect the
negative lead first (this is probably bare woven wire), so if
you touch the bodywork whilst loosening the nut (remember you
don't need to remove the nut) it won't matter, but if you still
have the negative connected whilst trying to remove the positive
and you touch the body you can weld you spanner to the battery,
that's frightening, I've done it.
There are things to look out for when the engine won't start,
does the starter motor click? Turn on the ignition, this can
make a small clicking noise as the relays turn themselves on,
but when you turn the key to the starter position is there any
noise? If there is a click, that is the solenoid that provides
the starter with the power to turn the engine over, if it
doesn't then you have no power to the solenoid which comes
straight from the ignition switch.
On a Beetle there is a connection under the back seat on the
opposite side to the battery, check that this is connected, it
should be red/black.
The coil is the tin can shaped thing with the thick black cable
coming out of the middle and going down to the distributor. It
should have a minimum of two wires attached to it, one to the
positive side (15) and one to the negative side (1). The
negative connection should come from the distributor and is
probably green whereas the positive lead on an aircooled VW is
usually black. Also on the positive side there is likely to be
a wire going to the carburettor to power the shut off valve and
the choke. To test these and any electric supply leads is with
a bulb with two wires soldered on, I use an indicator bulb. It
doesn't matter which way the bulb is connected to the electric
supply as the work both ways.
Wire has a set amperage, that is the maximum power that can be
drawn down it. For example you could not power your headlights
with the same wire you would use to feed your speakers. Wire is
measured in strands and strand thickness which gives a nominal
current draw. Here is am example, a roll of 14/0.30mm wire is
8.75amps, that means it has 14 strands of 0.30mm wire. The more
strands you have the more current can be passed down it. Any
wire must be fused between the supply (this is the battery) and
the load (this is the object taking the power) and must be
greater than the wires rating. You can calculate the required
fuse with this formula: Wattage / Voltage = Amperage. This is
best shown with spot lights, they are usually 55watts and the
battery is 13.2 with the engine running, so divide 55 by 13.2
and you get 4.2, so an 8 amp fuse would be suitable for this
lamp. Just remember each item on a line must be added together,
so if you have 2 spot lights on the same feed you will need to
double your figures, giving a maximum draw of 8.4 amps and
therefore a bigger fuse and thicker wire.
If you have a fuse that keeps blowing and you don't know what is
causing it, the only way to find out what it is is to switch
everything off then slowly turn everything on one item at a time
until the fuse blows again. Remember that it may not be single
item that is causing the fuse to blow, it could be too much draw
through one fuse and therefore when you have exceeded that the
fuse blows.
Turn signal indicators flag because a sprung plate is lifted and
dropped in a housing which makes then breaks contact at either
end of its travel. They are designed to cope with a certain
amount of current, usually 42 watts (2 bulbs) so if one bulb
blows at some time the other one will flash twice as quickly.
This is a good indication that one of your bulbs has blown.
A relay is a unit that allows a low power switch to turn on
something that requires a much higher draw. A good example of
this is a cheap plastic switch that comes with a set of spot
lights. Without a relay the switch would burn out. As I
mentioned before two 55 watt bulbs draw 8.4 amps and most
plastic toggle switches can only cope with about 2 amps, so you
fit a relay. The relay is only an electro magnet which when
turned on makes a separate contact. This means that the low
power circuit has no electrical contact with the high power
circuit. A relay usually draws less than 1 amp so almost any
switch will cope with this, and most relays can cope with about
30 amps.