Tdi Guy

Did you ever figure this out? I have a fuse panel with only 20 slots too and am trying to figure out what was what since I bought the harness and it did not come with the fuses in it.

Yes, that's where I will be going next. Will pull the starter and take a look. Just too cold here in USA this month. -5deg all week

So I replaced the ignition switch and now when I turn the key all I'm getting is the relay clicking behind the fuse panel. Nothing from the starter.

At least I'm not the only one. This is what I found. Switch is toast. Nothing else looks wrong. I was told the starter may have faulted as well

Yes, I would think that if you held the key on the glow plug cycle for too long you could heat up the wires and start a fire for sure don't you think?

Yes, the brown wires go to the ign switch and they are a bit toasty. Wondering if I need a complete new harness.

Purchased a 90 2.5td. Previous owner stated he tried to start it and it started to spark and smoke near the starter. I also see that the heavy gauge brown wires that go into the ignition switch have melted a bit at the terminals. What could have caused this. Not sure where to starts. Funny thing is I purchased another truck with the same setup 10 years ago for parts. It also had a complete electrical fire that started in the same area. Is this common with the 2.5td?

Does the switch just ground the relay to make it work? The switch has a 5 pin plug. Does anyone know what wires go where on the switch plug?