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Frederic

Alternator fuse blows when starting

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So we’re at the final stages of finishing up the Pajero but we’ve come across something that seems weird. When firing up the engine the 100amps alternator fuse blows. Alternator motor itself is fine, starter motor also replaced this morning. Checked most of the wiring now but nothing suspicious found. 

Any ideas guys ? 

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BUHAHAHAHAHAH, this happens the same with me long ago and spotted this after lots and lots of $hit.

My Pajero after an engine rebuild, doing first sidey and car went off. Came down started again, worked perfectly and then on next sidey car went off again.

Exited desert with two cars escorting me to home, nothing happened.

Went to the mechanic he literally pulled his hair as he can't spot the error.

Next mechanic came in and spot the fault in 30 minutes, engine main ECU wiring has been passed next to the manifold and melts the wire to short that monster 100 AMP fuse on battery.

Solution: ECU wire should be covered in heat resistant material and should not pass next to the exhaust manifold. If you want I can take my engine bay pictures and post to show the correct routing. You can refer to your old engine bay pic if you have it handy to find a sweet spot to secure those critical cables.

See you on Friday ;-)

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Hey buddy !

After installing my amp last year and using the same wiring route as the main ECU cables I’ve covered that complete wiring in this typical spiral cord thingy. We haven’t opened that one yet so that might be indeed the culprit.

Will definitely check it out  !

 

Edited by Frederic
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Also worth checking the engine main power line that feeds the spark plug coil maybe short and that's why engine not cranking and blowing the fuse. You need a big load to short that battery fuse, it cant be music system or light chewing this much.

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