(09-10-2024, 11:47 AM)Antdad Wrote: Relay which was totally cooked, somebody had replaced it with a 30A instead of 35A. Got me thinking as this seems to be a common fault would it be worth uprating the relay to 40A?
Don't think there has ever really been a problem with the relays overheating, just failing is the problem.
From your image, I don't think the problem was the relay being 30A [although that may not have helped] but I'm pretty sure when I replaced my relay on my B9 Multispace [2008 1.6Hdi XTR] the relay was actually plugged into a base and didn't have individual terminals.
I suspect what has happened to your vehicle is that in the past there has been a problem with the system and the original base was either damaged or broken and someone has just wired in a new [incorrect] relay and the wiring/terminals are not up to carrying the required current.
I suggest you follow the wires back to see if the wires are part of the original loom or have been spliced in.
If they are not part of the original loom then cut them back to where the splices are as they are obviously not the correct current carrying capacity.
If the wiring is part of the original loom, them you can get away with putting new terminals on the end but make sure they are rated to carry above the maximum current [35A] and crimp them on with a pair of good quality crimping pliers. Also when fitting new terminals, when you cut back the wires make sure where you have cut back to hasn't been affected by the overheating. In that I mean make sure the strands in the conductor can be separated and have not 'fused' into a solid lump, as that affects current carrying capacity quite severely.
The OEM Part number of the relay is OMRON 9620725080 rated at 35/15A [well that was the original fit on my 2008 Berlingo B9]
Finally if you haven't already bought a relay, I still have my original OMRON relay as listed above, as in my case it wasn't the fault [my fan had actually failed!] so I still have one sitting in the garage, which I could sell to you at a reasonable price. If interested send me a PM.
Edit: Had a quick look on-line to check I wasn't going completely mad and found some images [like the one below] showing the relay fitted into a base, so my memory was correct, in that there should NOT be separate terminals, so it definitely looks like someone has been playing with the wiring.
Relay fitted into base
Relay