Hi,

when I opened fuse box in engine bay, I spotted this "feature".

Hardwire connection between R1 (100) and F30 (Terminal X). 

Any Idea what might be giong on? (Can't get auto electrician appointmen sooner than late next week).

Thanks

At a guess the relay was not being energised so the coil has been hotwired or perhaps the relay has failed & they have hotwired the N.O contact, the latter less likely as it would have been easier to shunt and would not have been visible.

 

Well spotted & I hope you get it sorted.

Perhaps been done to bypass water damage/corrosion on the board underneath.

Thank you, that corrosion might be a clue, I'll have a look at it. I remember when I pulled one of the 50 ones out it was a bit stuck with kind of scale deposit on the pins. 

On later models which have different fuse box layout, one reason for a car not starting is corrosion of the fuse and fuseholder of a10A fuse at he bottom left (?) of the fusebox. Usually means putting in a new fuse box.

 

Once you have removed the battery, it looks like your fuse box can be taken out after releasing a few screws and a power connector.

Pikpilot thanks for your ideas. I'm experiencing bad winter starts with persistent p0684 error - interminent signal from glow plug control module. I'll remove the fuse box and check for damage on the bottom side, I suppose there will be a hidden gremlin. 

Did a little bit of homework. 

The relay is not sealed, the plastic cover is broken and 50A fuse doesn't get current on the pin, hence the hardwire. 

I went through the other fuses, scrape the scale deposits off and it seems to be better already, Glow plug light was shining much longer and car started on first turn. 

I ordered different fuse box so hopefully after swap it's gonna be no hardwire and good starts only. 

Glad you got it sorted. The previous owner should have put in a new fuse panel rather than trying a fix at one point which ignored potential problems elsewhere on the board.

 

Just make sure the fuse board is for the same model and year as they vary with fuel and options. 

The previous owner didn't have much clue, he was just having it serviced in one garage in Oxford. Maybe was them, maybe was even someone before, who knows. It's the same vag number part, same layout, with all fuses, relay and bridge on R2 position, so fingers crossed! I'll update here what the result is. 

More info on this topic.

Fuse box swapped, the old one has sustained some water damage. 

The hardwire problem is persistent. Without the wire Engine ECU is not communicating, so i put it back for the time being and will try to find out whether the fuse is feeding the relay or the other way and then investigate further on wiring.

Glow plugs seem to work now,