Man these upgraded fusebox designs are so nice.
This car has had endless fuse issues. I refurbished everything but ultimately the metal contacts were too fatigued and weren't gripping the fuses well enough.
I installed this today, which took maybe half an hour, then spent an hour or so trying to debug why the headlights were coming on with the parkers. Ultimately found that the headlight/parker relay, the cabin one you only get on later 240s, someone had replaced it with a 5 pin 87/87 relay, when it's supposed to be 87/87b.
It may seem like an inconsequential difference, but when open, an 87/87 has continuity between those pins, whereas an 87/87b does not, due to each pin having a dedicated switch in the relay.
I also rewired the central locking triggers (both the lock barrel and the pull knob sensors). The wiring was all perished and shorting. For the lock barrel switch, I took the switch completely apart, removed the contact sliders, cut the old wire off them and (painstakingly) soldered new connections. For the door pull I had just enough exposed wire to solder to. The wires were all oxidised, soldering them took a lot of cleaning and fluxing then boiling the flux with the iron, cleaning it up, repeating, until the solder wicked nicely into the wires.
It all works great now, except after one use of the key the barrel cylinder popped off, so I must not have properly clipped it in place. I had been at it for 8 hours by this point so decided to sort it out another day.
Next up will be new shocks on all corners, then of course the turbo swap, which will probably happen after Nats.
Cars are pain!
