Electrical Issues

[iluvm]

Hello I have a December 2004 Zetec Galaxy 1.9 TDI and started to get the Glow Plug light flashing.

After some checking and double checking of glow plug connections, I decided to book into Ford dealership as car still has warranty.

After many wasted phone calls to dealers who are not interested in warranty issues unless you are booking a service at same time, I thought I'll fix myself.

 

By this time the ignition light was staying illuminated as well and I was told that glow plug light is a general malfunction indicator. I found both brake lights not working and changed brake switch.

This cured the glow plug light flashing but not the illuminated ignition light and the battery was starting to go flat.

Voltage across battery with engine running 11.75 so no charge going into battery and then realised battery is only 70 AH / 340 A so replaced with new 80 AH / 800 A. Checked cable between alternator and battery, no continuity.

 

Opened fuse box by battery and found alternator wire/fuse box & 150 amp link starting to melt.

Cleaned up connection best I could but box/fuse link in a bad way, restarted engine and was getting 13.8 volts but wire getting hot at fuse box end after 5 mins of engine running.

 

Tomorrow I'm off to dealer to purchase new fuse box and fuse link, going to cut back and re-terminate alternator cable.

 

Should I be checking anything else as new battery was silver cadium and can not let that go flat? I presuming the melted box etc was down to bad/loose connection?

 

Any advice anyone?

[gregers]

personally if youve still got warranty on the car get them to sort it out(thats if it aint costing you)

[big_kev]

Get it done under warranty

[mumof4]

Ahh..melting main fuse feed box...had that twice on my car.Second time it blew the alternator.

 

Main fuse feed boxes are about 21 quid IIRC.It is best to replace the cable at the same time.As i didnt the first time it went and then it went poof not long after.

 

El Dingo has had the same problem aswell.

 

It could have been a bad/loose connection...or it could have been a speck of dirt on the connections.Must make sure that they are clean when you refit new box.

[iluvm]

If you can be without your car for a week and a half waiting for a warranty booking with no courtesy car for the day your car goe's in, then that is fine. Being without my car for just one day causes chaos in my household!

I tried three local Main dealerships, two were a week and a half wait, the other was 6 to 8 weeks wait!

I've bought the new fuse box and cut back / re-terminated cable, I'll let you know how I get on.

[iluvm]

Refitted alternator cable and new fuse box, good continuity between alternator and battery.

14.2 vdc across battery after restarting, this dropped to 13.5 vdc when air con, heated screen etc turned on but went back up to 14 vdc max when revved.

Cable and terminals cool both ends after 10 minutes of running, lets see how long it lasts!

Thanks for the advice and comments