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Battery cable sparks


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Posted

I just got done fixing some melted/brittle wires in my wiring harness (just the ones bundled with the injector wires). I also replaced the power cable between the alternator and starter. After I plugged everything back in and went to connect the negative battery cable, there were sparks and smoke from the battery terminal. After checking my connections I figured out that it only happens when the new alternator power cable is connected to the starter. I checked the cable and it's not shorting out anywhere and is wrapped in high-temp wire loom. Could my alternator be bad and cause this? When removing the alternator and old cable the first time, I had to take it apart to repair the post that the power cable goes onto. The post unscrewed from the alt. instead of the nut just coming off the post.

Posted

I accidentally pinched the wire by the alternator against the intake manifold in my 91 euro... and it did what you describe.

Posted

I think I figured it out, but it's dark out now so I'll have to wait and check tomorow... When I replaced the post on the alternator, there was a plastic piece between the post and body of the alternator. It was brittle and cracking, and now that I think about it may have been keeping the post from contacting the body of the alternator, which is grounded. I bet I tightened the post too much, it cracked the plastic washer-type thing, and is now grounding out against the alt. body. :redface:

Posted

that would be your problem. You may have to get another alternator unless you can figure something out to seperate the case and cable

Posted

Problem solved... It was my own stupid mistake mentioned above. I put a thick nylon washer between the terminal post and alt. body.

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