Electrical issue caused by melted wires

Tiny
VERONICA WIMMS
  • MEMBER
  • 2002 FORD FOCUS
  • 2.0L
  • 4 CYL
  • 2WD
  • MANUAL
  • 144,288 MILES
I have a 02 focus se manual 2.0 zetec that has melted wires from the starter to the battery 3 times now from falling onto the egr pipe. The 1st time it burned just the black wires from the starter to the batery the 2nd same ones plus the ignition coil harness the 3rd just the black wires only this time they melted a hole in the egr tube. Ive changed my plugs n wires the starter and tebuilt the altenator the crankshaft position sensor fuel filter battery and again all wiring and at 1st cud get it to attempt to start but not turn over now its doing the same as it did when the starter went out I turn thr key n get nothing all my dash lights come on but not ding click or sound from the engine I used a test light on the fuses both under the hood and under the dash on drivers side under the hood there 2 I no that are major fuses that didnt light uo then a small 1 only 1side lit up then at the bottom like 4or5 little ones didnt and when I push 1of the the small relays in it makes the headlights come on wo the key even in it under the dash theres some that didnt light up but based on the door to the fuse box they are 1s for the lights cig lighter nothing major ive checked all other wires even tho they havent melted and found no issue so whats your theorys or suggestions on what I can do to get my car going again
Tuesday, July 23rd, 2019 AT 4:14 PM

10 Replies

Tiny
SCGRANTURISMO
  • MECHANIC
  • 4,897 POSTS
Hello,

So when you turn your vehicle's ignition key to "START" does it sound like your starter is dragging or does the starter engage at all?

Thanks,
Alex
2CarPros
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Tuesday, July 23rd, 2019 AT 10:26 PM
Tiny
VERONICA WIMMS
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At first it was trying to start but now even after charging the battery it does nothing like when the starter went out ive been trying to trace the wires that didnt light uo to their source and find no breaks on them im testing all the sensors involveing anything in that area but idk how to use my ohm multi tester on them
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Saturday, July 27th, 2019 AT 1:10 AM
Tiny
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Hello again,

In the diagrams down below I have included directions for how to find opens in a circuit, shorts in a circuit, how to test a ground, and also how to find unwanted resistance or a problem in a circuit with a voltage drop test. Please go through these guides and get back to us with what you are able to find out.

Thanks,
Alex
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Saturday, July 27th, 2019 AT 1:51 AM
Tiny
VERONICA WIMMS
  • MEMBER
  • 144 POSTS
Thanku but idk how to use the multimeter il send a pic of it so maybe u can tell me what settings to use for what and do I have everything hooked up like car battery fuses in box sensors plugged up when doing said tests
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Saturday, July 27th, 2019 AT 9:02 AM
Tiny
SCGRANTURISMO
  • MECHANIC
  • 4,897 POSTS
Hello again,

Put the setting in DC Volts. It's the one that has a V then straight line on top/dots on bottom. There should be a setting there for 20, so 20 Volts DC. The red test lead should always go to positive and the black goes to negative, but don't worry if ya get em mixed up. For instance, if you were measuring the voltage of your vehicle's battery and got the test leads backwards instead of reading 12 Volts it would simply read -12 Volts. Here is a link for you to go to.

https://www.2carpros.com/articles/how-to-use-a-voltmeter

Please go through the guides and get back to us with what you are able to find, or if we can help in any other way.

Thanks,
Alex
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Saturday, July 27th, 2019 AT 9:55 AM
Tiny
VERONICA WIMMS
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  • 144 POSTS
Okay, so if I am checking a harness how do I hook it up and should the battery and everything else be hooked up?
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Wednesday, July 31st, 2019 AT 7:54 AM
Tiny
VERONICA WIMMS
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  • 144 POSTS
And I bought a aftermarket wiring harness for the crankshaft position sensor, but the wire colors don't match. How do I no how to connect?
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Wednesday, July 31st, 2019 AT 7:57 AM
Tiny
SCGRANTURISMO
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Hello again,

Okay, the brown/red wire on the original harness is the(-) negative wire and the white/red wire on the original harness is the(+) positive wire. I have also included a wiring diagram of your vehicle with the Crankshaft Position Sensor (CKP) wires highlighted for you and a diagram of the wiring harness connector for you in the diagrams down below. Please go through them and get back to us with how things turn out.

Thanks,
Alex
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Wednesday, July 31st, 2019 AT 11:40 AM
Tiny
VERONICA WIMMS
  • MEMBER
  • 144 POSTS
On the new harness both wire are white only, but when I am trying to use the ohm multi tester. Does the cars battery need to be in it hooked up and the fuses as well? When testing the harness does the red go on one side black on the other? And do I turn it on before I i hook it to the harness?
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Wednesday, July 31st, 2019 AT 6:38 PM
Tiny
SCGRANTURISMO
  • MECHANIC
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Hello again,

In the last reply I sent you a diagram of the electrical connector for your vehicle's CKP sensor. This is the connector from the vehicle's wiring harness. Orientate the new connector you are installing exactly like it is in the diagram. The way to orientate it is by where the tab is on it. The tab is what snaps and locks the connector in place on the sensor itself. The pins are then numbered with wire colors assigned. The wire colors are the wire colors of the vehicle harness. It don't matter what the color of the wires on your new connector are, they are not important, just get the vehicle harness wires correct and you are done. And yes, the battery should be disconnected whenever you are working on your car any time, except when it needs to be hooked up for electrical measurements. Please get back to us with how things turn out.

Thanks,
Alex
2CarPros
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Thursday, August 1st, 2019 AT 1:14 AM

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