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  #16  
Old 03-01-2013, 04:40 PM
oab_au oab_au is offline
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Re: Total shutdown with elect power suging and fried fusible link

Quote:
Originally Posted by 1986nate View Post
Replace your alternator....
the regulator is internal and is what causes this. So there is no prevention.
We can't prevent the regulator from failing. , but we can prevent it from destroying a lot of electrical components in the process.

If you look in this thread, at post 15, it shows how to reconnect the alternator wiring to prevent this trouble. Post 27 explains why it happens.
http://www.subaru-svx.net/forum/showthread.php?t=49727

It is not a difficult job to do, but good insurance.


Harvey.
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  #17  
Old 03-01-2013, 06:03 PM
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Re: Total shutdown with elect power suging and fried fusible link

So basically what you're saying is that I need to put another 100+ amp fuse on the alternator output? Here is what my wiring currently looks like: http://www.subaru-svx.net/forum/showthread.php?t=58723
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  #18  
Old 03-01-2013, 06:05 PM
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Re: Total shutdown with elect power suging and fried fusible link

.

Its the new alternator wiring modification in the How-To Documents HERE

The two wires that were shortened were originally joined together at the alternator post, all that had to be done was to remove them from the alternator post, shorten them and connect them together.

This restores the original circuitry and its inherent safety elements, but excludes the original alternator output, which now has its own dedicated, fused line to the battery.

Implementing this modification is easy, safe and removes and isolates the alternator output from the rest of the electrical system. As it seems that the voltage regulator within the alternator is the weak link and is most prone to go bad, most would want to guard against it. This does exactly that.

This modification had been in place on my 96 Polo since February, 2010 with zero problems.

.
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JFICX8659TH100216.....Date of Manufacture: November 16, 1995.....
Fuji Heavy Industries..Ōta North Plant....Ōta City,. Gunma Prefecture, Japan

In-Service Date: January 2, 1997



"The Pristine Green Polo Machine”
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HID lighting (5000K) for headlight and H3 fog lights, PIAA SuperExtreme 120W high beams, rebuilt EG33 longblock, Cometic head gaskets, Phase II flexplate, AMR aluminum radiator with custom silicone hoses, 160A high-output alternator in aluminum-ceramic coated case, new design alternator wiring upgrade v.4, rare factory headlight protectors, refinished JDM BBS mesh aluminum wheels and custom, polished billet aluminum new hex center caps, LED grille mod, R1 Concepts high-carbon cryo slotted rotors, Akebono ceramic pads, Goodridge S/S braided brake lines, Smallcar Stage 1 shift kit, ThermalTech aluminum/ceramic-coated valve covers, Energy Suspension urethane front & rear swaybar bushings, Bontrager22 rear swaybar with QS Components Chromoly Teflon/Kevlar endlinks, "$15.00/5 minute" suspension mod. Hella Supertone horns, Custom stainless steel exhaust system with 2" headpipes, Magnaflow cats, AeroTurbine AR25 resonator /AWD "Bullet" muffler.


R.I.P. 2010 Subaru Outback Limited 2.5 CVT...338,000 miles. Totaled by a 1,300 lb. COW March 4, 2016

2014 Hyundai Avante Limited ...178,000 miles. Actually quieter and smoother than the Outback

2007 Mazda Miata MX-5 PRHT...102,000 miles.
Plenty of parts, service and windshields.


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Last edited by svxcess; 03-04-2013 at 08:47 AM.
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  #19  
Old 03-04-2013, 06:27 AM
macadamianut macadamianut is offline
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Re: Total shutdown with elect power suging and fried fusible link

ECU/TCU on the way. Will test and report back.

Thanks for the help.
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  #20  
Old 03-04-2013, 03:04 PM
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Re: Total shutdown with elect power suging and fried fusible link

Quote:
Originally Posted by macadamianut View Post
ECU/TCU on the way. Will test and report back.

Thanks for the help.
Sounds good. If the pump doesn't run go for the relay.

Harvey.
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  #21  
Old 03-04-2013, 04:22 PM
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Re: Total shutdown with elect power suging and fried fusible link

A great diagnostic and how-to thread. I look forward to a successful closure.
Gene
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  #22  
Old 03-12-2013, 08:42 AM
macadamianut macadamianut is offline
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Re: Total shutdown with elect power suging and fried fusible link

Okay sad news,

ECU replaced and ignition fuse pops when key is switched the on position. Even before cranking. Fusible link stays good.


What next? Ground issue somewhere?
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1995 SVX-L AWD, green, 98,xxx miles, ECUtune 1.5, mazda RX-8 wheels with subie center caps, stebro muffler, resonator delete, koni inserts, perrin crank pulley, hella 500 off-road lights, power-slot rotors and .....
1993 968 Coupe 6-speed, 80,xxx miles black, H&R springs

Last edited by macadamianut; 03-12-2013 at 08:44 AM.
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  #23  
Old 03-12-2013, 12:47 PM
macadamianut macadamianut is offline
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Re: Total shutdown with elect power suging and fried fusible link

Quote:
Originally Posted by macadamianut View Post
Okay sad news,

ECU replaced and ignition fuse pops when key is switched the on position. Even before cranking. Fusible link stays good.


What next? Ground issue somewhere?

Is the ignition fuse connecting the starter and ignition switch? Is it worth looking into the switch?
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1995 SVX-L AWD, green, 98,xxx miles, ECUtune 1.5, mazda RX-8 wheels with subie center caps, stebro muffler, resonator delete, koni inserts, perrin crank pulley, hella 500 off-road lights, power-slot rotors and .....
1993 968 Coupe 6-speed, 80,xxx miles black, H&R springs
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  #24  
Old 03-12-2013, 04:39 PM
oab_au oab_au is offline
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Re: Total shutdown with elect power suging and fried fusible link

As I said before, "Yes that looks likely. Fuse16 feeds the ECU, but also the fuel pump relay, that would have been closed when the surge happened.
So If the fuel pump won't run, even with another ECU have a look at that."

If you can find the pump relay, (don't know where it hides,) and unplug it to see if that is the problem.

Harvey.
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  #25  
Old 03-13-2013, 03:49 PM
oab_au oab_au is offline
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Re: Total shutdown with elect power suging and fried fusible link

John, I think this needs its own thread. Macs problem has not been resolved yet.

Harvey.
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  #26  
Old 03-15-2013, 01:24 PM
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Re: Total shutdown with elect power suging and fried fusible link

Harvey,

As per your previous suggestions:

1. Tried unhooking the fuel pump relay (both relays, not sure which is the fuel pump) under the dash attached to the steering column which still popped fuse 16 when ignition switched to ON position. So no joy there.

2. All fuses out of underhood box. Replaced one at a time until interior ignition fuse #16 popped.

It appears that SBF #4 slow blow fuse #4 is the circuit the fault is on. The SBF's themselves are not blown.

Also to mention that the car will crank even though fuse 16 is blown. All accessories still work. Wipers, climate, radio, windows, hazards, etc.

The quick connect to the alt voltage regulator has two wires that both look like they had gotten pretty hot.

Hope this info helps to narrow things down.

Thanks,
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1995 SVX-L AWD, green, 98,xxx miles, ECUtune 1.5, mazda RX-8 wheels with subie center caps, stebro muffler, resonator delete, koni inserts, perrin crank pulley, hella 500 off-road lights, power-slot rotors and .....
1993 968 Coupe 6-speed, 80,xxx miles black, H&R springs
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  #27  
Old 03-16-2013, 06:23 PM
oab_au oab_au is offline
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Re: Total shutdown with elect power suging and fried fusible link

Quote:
Originally Posted by macadamianut View Post
Harvey,

As per your previous suggestions:

1. Tried unhooking the fuel pump relay (both relays, not sure which is the fuel pump) under the dash attached to the steering column which still popped fuse 16 when ignition switched to ON position. So no joy there.

2. All fuses out of underhood box. Replaced one at a time until interior ignition fuse #16 popped.

It appears that SBF #4 slow blow fuse #4 is the circuit the fault is on. The SBF's themselves are not blown.

Also to mention that the car will crank even though fuse 16 is blown. All accessories still work. Wipers, climate, radio, windows, hazards, etc.

The quick connect to the alt voltage regulator has two wires that both look like they had gotten pretty hot.

Hope this info helps to narrow things down.

Thanks,
Mac I see in the Supplementary book for the 95, that the Fuse 16 also feeds the Air bag system. So if you can unplug the Air bag control unit, then see if the short has gone.
I don't know much about the wiring for the Air bag system, but it does warn to "disconnect the Neg battery terminal for 20 seconds before doing anything to the Air bag system.

Harvey.
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Tell it like it is!

95 Lsi. Bordeaux Pearl, Aust. RHD.149,000Kls Subaru BBS wheels.
97 Liberty GX Auto sedan. 320,000Kls.
04 Liberty 30R Auto Premium. 92.000kls.
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  #28  
Old 03-16-2013, 11:34 PM
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Re: Total shutdown with elect power suging and fried fusible link

So that you do not keep using up fuses, connect a 12 volt bulb in place of the fuse. If with the ignition ON, there is a short circuit the bulb will light up. If you clear the short the lamp will go out. Do you have one of those cheap test lamps with probes?

Regarding fuse 16:

The ignition coils are supplied via fuse 16. Disconnect the grey colored 8 pin plug B4 from socket E3 which you will find on top of the engine towards the rear and connected to a lead running through the bulkhead. See if the short circuit remains.












Are there any aftermarket accessories which have been added to the car, and which only operate when the ignition is turned on? Is there any wiring left in place which could have been left over from an accessory which has been removed and which could be shorting?


In my past experience, when everything electrically was working as it should and then a problem or symptoms suddenly appears, think back to the last thing that you did before the problem occurred. I have undone a mod or two and the problem went away.

.
Attached Images
File Type: jpg Fuse 16.jpg (115.3 KB, 1635 views)
File Type: jpg connector 1.jpg (85.1 KB, 835 views)
File Type: jpg Clipboard02.jpg (53.5 KB, 791 views)
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1996 Polo Green LSi #216..138,100 miles...SOLD

JFICX8659TH100216.....Date of Manufacture: November 16, 1995.....
Fuji Heavy Industries..Ōta North Plant....Ōta City,. Gunma Prefecture, Japan

In-Service Date: January 2, 1997



"The Pristine Green Polo Machine”
First Polo Green on the Network
First Clear front turn signals, JDM Alcyone hood emblem, rear panel, and BOXER engine cover on the Network (US) (2000)
First 5000K HID factory fog lights (2007)
First SVX JDM BBS wheels on a USDM SVX (2013)

HID lighting (5000K) for headlight and H3 fog lights, PIAA SuperExtreme 120W high beams, rebuilt EG33 longblock, Cometic head gaskets, Phase II flexplate, AMR aluminum radiator with custom silicone hoses, 160A high-output alternator in aluminum-ceramic coated case, new design alternator wiring upgrade v.4, rare factory headlight protectors, refinished JDM BBS mesh aluminum wheels and custom, polished billet aluminum new hex center caps, LED grille mod, R1 Concepts high-carbon cryo slotted rotors, Akebono ceramic pads, Goodridge S/S braided brake lines, Smallcar Stage 1 shift kit, ThermalTech aluminum/ceramic-coated valve covers, Energy Suspension urethane front & rear swaybar bushings, Bontrager22 rear swaybar with QS Components Chromoly Teflon/Kevlar endlinks, "$15.00/5 minute" suspension mod. Hella Supertone horns, Custom stainless steel exhaust system with 2" headpipes, Magnaflow cats, AeroTurbine AR25 resonator /AWD "Bullet" muffler.


R.I.P. 2010 Subaru Outback Limited 2.5 CVT...338,000 miles. Totaled by a 1,300 lb. COW March 4, 2016

2014 Hyundai Avante Limited ...178,000 miles. Actually quieter and smoother than the Outback

2007 Mazda Miata MX-5 PRHT...102,000 miles.
Plenty of parts, service and windshields.


4th Registered Network member —2/21/2001

My NEW locker..I...My Email..I..Wikipedia/SVX .

.

Last edited by svxcess; 03-18-2013 at 07:00 PM.
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  #29  
Old 03-18-2013, 02:38 PM
macadamianut macadamianut is offline
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Re: Total shutdown with elect power suging and fried fusible link

Okay, will check for errant accessory wires and try the B4 E3 disconnect.

What is on the slow blow fuse #4 circuit?

Will also try disconnecting all airbag related devices to see if it is in there. Disconnect both battery leads for 10 minutes first? I think I read that somewhere.

Thanks,
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1995 SVX-L AWD, green, 98,xxx miles, ECUtune 1.5, mazda RX-8 wheels with subie center caps, stebro muffler, resonator delete, koni inserts, perrin crank pulley, hella 500 off-road lights, power-slot rotors and .....
1993 968 Coupe 6-speed, 80,xxx miles black, H&R springs
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  #30  
Old 03-18-2013, 05:25 PM
oab_au oab_au is offline
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Re: Total shutdown with elect power suging and fried fusible link

Quote:
Originally Posted by macadamianut View Post
Okay, will check for errant accessory wires and try the B4 E3 disconnect.

What is on the slow blow fuse #4 circuit?

Will also try disconnecting all airbag related devices to see if it is in there. Disconnect both battery leads for 10 minutes first? I think I read that somewhere.

Thanks,
SB fuse 4 supplies all the ignition circuits.
So if you can tell if the short happens on which of the three positions;
When the key is turned to Acc
Or when turned to ignition ON.
Or when you turn the key for the starter to work.
We can look at those circuits.

Harvey.
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Tell it like it is!

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97 Liberty GX Auto sedan. 320,000Kls.
04 Liberty 30R Auto Premium. 92.000kls.
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