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  #1  
Old 01-12-2014, 06:19 PM
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NSTG8R NSTG8R is offline
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'Battery warning' light with key out...

Okay...Just drop the engine back in the car after replacing the torque converter seal (HUGE PITA!). Fired right up, purrs like a kitten, but there's something strange going on. The battery warning light is on, even after the key is removed . I went ahead and drove it home (pulled engine at a buddy's garage) and got a 'check engine' light. Will check to see what the code is tomorrow, but I've never seen a situation where the "battery warning" light is on once the ignition is off.....disconnected the battery. Anybody ever have this happen?
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  #2  
Old 01-13-2014, 08:55 AM
92snowmachine 92snowmachine is offline
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Re: 'Battery warning' light with key out...

check for a short to ground on the brown wire at the alternator.
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  #3  
Old 01-13-2014, 10:36 AM
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Re: 'Battery warning' light with key out...

Brown wire from alternator, thanks for the tip, will do when I get home tonight. Really need to give it another once over to make sure I didn't pinch any wires while I was cranking bolts down.

Is it possible that the ECU is 'smart' enough to detect a dead cell in the battery causing a warning light? It goes off when the cars starts (although I did get the "check engine" light about half mile into the trip home). Probably wishful thinking, since when this car was built (92), the internet was just a baby, and cell phones were as big as bricks.
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  #4  
Old 01-13-2014, 11:24 AM
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Re: 'Battery warning' light with key out...

.

You may quite possibly have a break in the field wire at the alternator plug (thin wire) or along its length. Could also be a short between the two wires at the plug.
It is power from this terminal that turns off the idiot light. The wire may appear brown, but was once white and has darkened with age and heat.







There are two wires coming out of the alternator plug on the side if the alternator. The larger wire is the sense wire and the smaller, thinner of the two wires is the FIELD wire (properly called the "field exciter tap")

This terminal is fed by the switched 12V source (from the ignition switch and through the ignition warning light indicator or "idiot light"). It is used to energize or excite the field windings inside the alternator. The alternator cannot start charging until there is voltage on the field windings and a magnetic force is created. In addition, this terminal will cause the ignition warning light to illuminate if the ignition is turned on and the alternator is not supplying enough voltage.

The field wire can tell you that the alternator is actually working properly by being hooked to the alternator light on the dash. This saves the car companies from having to install a voltmeter, by instead having a low-cost idiot light on your dash! So when you turn the ignition on, the ALT light should go on, then when the car is running, the ALT light should go off.



If a shorted or damaged field wire is not the problem, read on...

From a logical basis, the alternator/battery warning light cannot normally be illuminated separately, as all the lamps depend on the same positive circuit, connected via the ignition switch. This leaves the possibility of a back feed to positive, via another component. Usually though a back feed results in the engine continuing to run after the ignition is turned off

Is the ALT/BATT lamp at full brilliance when the ignition key is removed?
Is there an increase in brilliance when the ignition is turned on?
Is any other lamp partially illuminated and if so which? This may need checking in near dark conditions.

Carefully check that all alternator connections are correct. In view of the engine removed situation, this is most logically the possible location of the problem

Disconnect the alternator plug connection and see if the fault remains.
Do the same with the main terminal connections.


My bet is on the alternator plug wires, since that was probably the last thing you did. When doing my alternator wiring upgrade, I replaced the plug and wires as engine heat and age had made them brittle. Make sure to mark each wire as you splice in the new plug. While the original wires are different thicknesses, the replacement plug has wires which are the same thickness.






The replacement part number for the SP Alternator Harness Repair Plug is PLUG300 and is available from Maniac Electric Motors HERE


Call Christian at (972) 557-5768 and tell her what you need


.
Attached Images
File Type: jpg Alternator wiring 1.jpg (183.4 KB, 931 views)
File Type: jpg Alternator plug 1.jpg (310.5 KB, 1074 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)
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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; 04-25-2014 at 07:26 AM.
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  #5  
Old 01-13-2014, 11:34 AM
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svxcess svxcess is offline
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Re: 'Battery warning' light with key out...

The field wire connects through the ignition switch. If the light goes out when your engine is running, it appears that the circuit is functioning normally. Turning the engine off causes the light to come on (this is normal)

A dead cell in the battery will not trigger a warning light. The signal comes from the alternator through the ignition switch to the light

The enigma is that when you turn the key completely to the OFF position (the light should not be illuminated in this position, whether or not the key is in the ignition )

Possibly something within the ignition switch...?

.
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Subaru Ambassador

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; 01-13-2014 at 12:17 PM.
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  #6  
Old 01-13-2014, 05:29 PM
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NSTG8R NSTG8R is offline
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Re: 'Battery warning' light with key out...

SVXCESS was 100% correct! Turns out when I reattached the alternator plug, I twisted it. The brittle insulation cracked off, and twisted the bare wires together. Had to do the electrical tape trick for now, but I'll be rewiring it ASAP the way you described. BIG THANKS!!
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  #7  
Old 01-13-2014, 05:39 PM
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svxcess svxcess is offline
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Re: 'Battery warning' light with key out...

Glad it worked out. That's why they call me sx-XCESS, because sometimes it takes me 100 sentences to define a problem that it took 92snowmachine only 1 sentence to solve.

Like I said, if everything was working fine previously, check the last things you did. Brittle, aging wires, like vacuum lines, can create all kinds of havoc.
.
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Subaru Ambassador

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; 04-25-2014 at 07:25 AM.
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  #8  
Old 01-13-2014, 06:30 PM
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NSTG8R NSTG8R is offline
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Re: 'Battery warning' light with key out...

Nothing wrong with being thorough! I really appreciate the input and part numbers. Couldn't find the connector on the link, but I emailed them with the part number you included in your "illustrated tech article [highly awesome]", and with any luck, I'll be rewired in a week or so. Thanks again to you and 92snowmachine!
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  #9  
Old 01-13-2014, 06:56 PM
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svxcess svxcess is offline
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Re: 'Battery warning' light with key out...

The link should work, as I just tried it.

SP Alternator Harness Repair Plug
Item #: PLUG300
$14.95



Make sure to look at the way the wires come out of the original plug and match them up to the new plug.

I know that technical modification V.4 by heart and I didn't remember ever putting in the link to the alternator plug. I just checked and it wasn't mentioned. Where did you look to get that number?

Call Christian at (972) 557-5768 and tell her what you need.

.
Attached Images
File Type: jpg Alternator plug.jpg (18.9 KB, 758 views)
__________________
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Subaru Ambassador

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; 01-13-2014 at 07:10 PM.
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  #10  
Old 01-14-2014, 07:56 AM
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NSTG8R NSTG8R is offline
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Re: 'Battery warning' light with key out...

Just "Binged" AF-50-12252, and one of the sites listed it as a AMFOR part (looked like a tractor-trailor website). I did email Christian and hopefully he can hook me up with a new plug (no pun intended).

And as a side note, drove the car to work this morning...no leaks , and ran like a raped ape (not sure who penned that analogy, but it rhymns).
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  #11  
Old 01-14-2014, 03:35 PM
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svxcess svxcess is offline
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Re: 'Battery warning' light with key out...

Now that the problem has been solved, here is what probably happened:

The short circuit at the alternator plug provided a sneak circuit for positive voltage to the ignition circuit, with the non-energized regulator providing a ground for the lamp, causing it to illuminate.

This resulted in a sort of out of balance bridge network and the lamp cannot have been fully illuminated.

The original part number for the plug, and the supplier, is now useless for our needs. Just get the alternator plug directly from Maniac.
.
__________________
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Subaru Ambassador

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 .

.
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  #12  
Old 01-15-2014, 07:47 AM
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Re: 'Battery warning' light with key out...

Got one ordered! Thanks again for all your help!
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