Auxiliary Fuse Box

Fuse Panel Wiring

11/2/07

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Pioneer DEH-P980BT | Pioneer CD-IB100II iPod Adapter | Pioneer GEX-P920XM  XM Digital Satellite Tuner | Pioneer GEX-P10HD HD Radio | Pioneer CD-UB100 USB Adapter | Auxiliary Fuse Box | Infinity Basslink | Infinity 3022cf Rear Speaker Array

 

 

Power

One of the dirty secrets of the early phases of the sound system project was the hoard of cigarette lighter plugs that was strapped to the transmission tunnel on the passenger side, inside an organizer.   Not very nice...

GPS V, GPSMap 76CSx, XM Radio (Roady XT)

I was determined to get rid of them as soon as possible.  I wanted to put in switched and un-switched panels to support both needs.  I priced Painless Wiring fuse panels and opted to replicate them with parts sourced locally.  Here's a list of the parts used in the event you wish to order them online and save gas and a trip to the store.

Product Mfg Part#  
ATC Blade Type Fuse Panel Buss BP/15600-06-02
Automotive Wire 12 gauge red ElectroForce 89325
Automotive Wire 12 gauge black ElectroForce 89324
Automotive Wire 10 gauge red Painless Wiring  

30 Amp Circuit Breaker with Mounting Bracket Buss BP/CBC-30HB
Fuse Assortment ATC Blade Buss AK-6
Repair Tape SealWrap http://www.sealwrap.com/tapedata.html
Multi-Colored Electrical Tape    
All Weather Power Outlet casco 212711C
4 Pin 30 Amp 12 Volt Relay Conduct Tite 84601
European Vehicle Antenna Adapter Cable Kit Antenna Works 40-EU30
Fuse Tap Buss
BP/HHA ATC Fuse Tap
Non-Metallic Single Gang Switch and Outlet Box Carlon B118AB-UPC

While installing the new head unit, I added new fuse panels for the power leads going to the Harman/Kardon Drive+Play for switched and un-switched 12v power and ground.  This provides auxiliary power options for these and future devices.

Fuse Panel Wiring

Buss Fuse Panel Buss Fuse Panel

 

The wiring plan takes power directly from the battery, through a 30 amp circuit breaker. 

30 amp circuit breaker

This reduces the risk of fire from the hot lead from the battery passing through the firewall.  Even with fuses for the components inside the cabin, the run of wire from the battery to the firewall could fault and cause a fire without a breaker of some sort.

The un-switched fuse block provides power at all times no matter the car is on or off.  I like to use this for the GPS, XM Radio, and is required for one terminal in the Drive+Play.  After a few generations of changes, this is the current set of connections to the auxiliary fuse panel.

Auxiliary Fuse Box Connections

The two fuse panels, once assembled were placed into slightly modified plastic switch boxes purchased at Lowe's. 

Switch Box

I removed the nails and cut access in the sides of the boxes to the fuse output terminals for the leads to the various accessories.  Once assembled I put standard plastic blank-out covers to keep the hot terminals from shorting against anything in the car.

The switched fuse block is controlled by a 30 amp relay that is activated by a switched lead (terminal 86; terminal 85 is grounded to chassis) from the original fuse box.

Bosche Type Relay Bosch-type 12v Relay diagram

When the car is on, the activating lead (86) switches the relay to provide power to the fuse box (power supply connected to terminal 30; terminal 87 provides power out when relay is "on").  This relay does not provide terminal 87a which would give power out when switch is "off".  When the car is turned off, the switch lead power drops, allowing the relay to disable power from the battery.

Power Lead WireGround Lead Wire

The leads come through the firewall using a factory-installed plug that has provisions for wiring to pass through.  I simply removed the battery and battery tray

Crossfire Firewall Plug under battery tray
Crossfire Firewall Plug under battery tray

With the switching and power wires through the firewall (they come into the passenger cabin under the floor near the amplifier), I ran the switching wire along the existing harness over to the auxiliary fuse panel near the brake booster on the drivers side.

Relay Activation Lead Path on Cowl

 Here, I added the fuse tap to the existing auxiliary fuse panel.  I removed the 15 amp fuse from socket 5 (the switched power lead to the stereo), put the fuse onto the fuse tap and added a second fuse for the new lead it adds (not shown in picture for clarity), then put the cover back on the fuse panel.  That was easy!

Buss Fuse Tap

Relay Activation Lead Piggy-back fuse holder

 

Fuse Box with Stereo lead and Wireless Locking Buzzer leads

Update:  6/28/08 I learned from another project when I installed a buzzer to route the red stereo wire and the leads for the buzzer through a rubber port provided for this purpose.  The wires go into some plastic conduit that I installed to help keep the wires protected and dressed.

Route for wires into Fuse Panel Box

Here's another shot of the port with a white wire coming out of it.  It's located on the front left side of the fuse compartment (facing the windshield of the vehicle).

Auxiliary Wiring Port

 

Next I put a spade connector on the positive battery terminal and installed the 20 amp circuit breaker between the battery and the hot lead that goes through the firewall into the passenger compartment. 

This lead provides power to both new fuse panels - one directly and the other through the relay that is switched by the lead attached to the fuse panel as just described.  This approach provides safe power to a number of accessories without modification to any of the car's fuse boxes or harnesses.

Each accessory is added by putting spade connectors on the end of the hot wire(s), and an eyelet connector on the ground wire.  The hot wires are connected to available fuse rows in the panel ("always on" or "switched").

I placed the auxiliary fuse box under the floor with the factory power amp - instructions here show where - stop after step 5 - you do not need to remove the amplifier from the panel to install the auxiliary fuse box:



        

      


Here is a logical diagram of the stereo system

 

Pioneer / Infinity Sound System
  Radio Devices   External Devices
  Sat Antenna   Antenna   USB Device iPod Music Phone   Generic Device
  Cable   Cable Splitter   USB Cable iPod Cable Blue Tooth   Mini Cable
  Pioneer GEX-P920 XM Satellite Digital Tuner   Pioneer GEX-P10HD HD Radio   Pioneer CD-UB100 USB Adapter Pioneer CD-IB100II iPod Adapter          
                       
Source XM   External 1   External 2 iPod   BT Audio Phone   Aux  
                         
  XM Satellite Radio   HD Radio   USB              
                         
                         
  AM   FM     CD                
          Pioneer Premier DEH-P980BT IP-BUS            
   
Blue Tooth    
 
 Auxiliary Stereo Cable
 
Head Unit
  Left   Right
  Factory Tweeter Factory Power Amp Factory Tweeter
Front Factory Mid-range   Factory Mid-range
  Factory Sub-Woofer Added Speakers Factory Sub-Woofer
     
Rear Infinity 3022cf
Speaker Array
Infinity Basslink
Powered Sub-Woofer
Infinity 3022cf
Speaker Array
Sub    

 


 

The wiring chart below illustrates the configuration and additional pages added to the web site explain the Pioneer DEH-980BT head unit, iPod Adapter, XM Tuner, HD Radio, USB Adapter, Infinity 3022cf rear speaker array, and Infinity Basslink installations. 

Here is the updated component layout and wiring.  The major components may be clicked to see more details about them.

 

Pioneer System Diagram with Component Wiring

Updated Component Wiring Diagram (click on components for write-ups)

 

 

Pioneer DEH-P980BT | Pioneer CD-IB100II iPod Adapter | Pioneer GEX-P920XM  XM Digital Satellite Tuner | Pioneer GEX-P10HD HD Radio | Pioneer CD-UB100 USB Adapter | Auxiliary Fuse Box | Infinity Basslink | Infinity 3022cf Rear Speaker Array

 

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