Electrical wires melted no power now

Tiny
VERONICA WIMMS
  • MEMBER
  • 2002 FORD FOCUS
  • 2.0L
  • 4 CYL
  • 2WD
  • MANUAL
  • 147,000 MILES
My battery wire, the plug from it to the spark plug wire box and another wire that all connect to the positive cable fell onto a hot pipe burning the wire from the alternator half way to it and slightly melting the other wires causing all power to go out of the car I cut the burned wires and reconnected them at a unburned spot w but connectors and still nothing my fuse panel has a slight burned smell what can I do or is the car now a total loss can it be a fuse, battery maybe I have just this week put a new starter alternator and start relay on the car.
Friday, June 14th, 2019 AT 7:40 AM

44 Replies

Tiny
KASEKENNY
  • MECHANIC
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Hi Veronica,

I think you are close to what the issue is. The fuse panel more than likely has an issue. That burning smell is not normal and you need to find where else you have melted wires.

What I suspect happened is when the insulation melted on the wires that touched the hot pipe, they shorted out the fuses or even melted the fuse panel. Unfortunately, any time this happens, you need to take a test light and find out what has power and what doesn't on the fuse panel. Whatever does not have fuel you need to replace the fuse and or wiring until power is restored.

The vehicle is not a total lose, it is just going to take some time to go through all that you need to and restore the power. Hopefully it is just fuses but again, there is no way to know without testing.

Here are some guides that will help with this type of testing:

https://www.2carpros.com/articles/how-to-check-wiring

https://www.2carpros.com/articles/how-to-use-a-test-light-circuit-tester

Please let me know if you have more questions.
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Friday, June 14th, 2019 AT 2:53 PM
Tiny
VERONICA WIMMS
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Well, I took another battery the next day and got it to start and drive only it has very little power and makes a noise which is similar to the things it was doing before the melt down when I had to replace the electric plug that goes from the box the spark plug wires go into then to the positive cable. So I have reordered that plug it comes tomorrow. I am hoping that is the last of my issue. I will let you know. But do you happen to know where I can find the exact fuse diagram and labeling for my car? I have been trying I need it for both under my hood and dash on drivers side as there is not one on the passengers. Again its 8th VIN numbers a 3 not p thank you in advance. This sites awesome.
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Monday, June 17th, 2019 AT 9:04 AM
Tiny
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Here are all the details out of the service manual. Please let me know if you need more information.
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Monday, June 17th, 2019 AT 1:02 PM
Tiny
VERONICA WIMMS
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  • 144 POSTS
Yes, I am replacing the ignition coil plug that burned and when I removed it the wires came out from the butt connectors and now I am not sure which wire to connect to what. Because on the new plug they are all black but on the car they are green and blue green and black and orange and black. Can you tell me which is first, second and third please?
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Tuesday, June 18th, 2019 AT 9:17 AM
Tiny
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Okay. Just want to make sure but your wires should be black and orange, green and blue, and black and green.

Here is the pin out chart for this connector.
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Tuesday, June 18th, 2019 AT 10:49 AM
Tiny
VERONICA WIMMS
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Okay, so I fixed my issue on that and even used zip ties to hold it away from the pipe again. I drive my car down the street and on my way back it starts stuttering. I get it home and the positive wire had some how fallen again onto the same metal pipe and this time it melted a hole in the metal pipe. Is there a way to fix this hole in the pipe? I will send pictures in just a seconds.
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Friday, June 21st, 2019 AT 8:01 AM
Tiny
VERONICA WIMMS
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Here is what the hole looks like. Is it possible to patch some how?
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Friday, June 21st, 2019 AT 10:18 AM
Tiny
VERONICA WIMMS
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Here is another shot of it:
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Friday, June 21st, 2019 AT 10:19 AM
Tiny
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That looks pretty significant. I would not try to repair it. I would just replace it. It is possible to repair but it will take welding a patch piece on this pipe but by the time this is done, it could have been replaced.

However, before you do that, I would make sure we secure that cable so the new pipe or something else doesn't get damaged.
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Friday, June 21st, 2019 AT 6:20 PM
Tiny
VERONICA WIMMS
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Do you know what the pipes called so I can price it?
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Saturday, June 22nd, 2019 AT 12:33 PM
Tiny
VERONICA WIMMS
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I used fiber fix on the pipe and fixed the wiring but the car wont turn over.
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Saturday, June 22nd, 2019 AT 12:34 PM
Tiny
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I would treat this like this is the first thing that has happened. Check for power at the starter. Do the lights in the cluster turn on?

I suspect if the lights on the dash come on, then you don't have power at the starter due to a faulty (burned) wire from the battery to the starter. Then check the relays and fuses again and make sure they were not damaged.
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Saturday, June 22nd, 2019 AT 4:54 PM
Tiny
VERONICA WIMMS
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Okay, yes I was thinking along those lines also.
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Sunday, June 23rd, 2019 AT 6:40 AM
Tiny
VERONICA WIMMS
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I will let you know soon. Thank you
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Sunday, June 23rd, 2019 AT 6:42 AM
Tiny
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Okay. Sounds good. I am here if you need more assistance. Thanks
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Sunday, June 23rd, 2019 AT 11:29 AM
Tiny
VERONICA WIMMS
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So yes the wire from starter solenoid was burnt and now the bolt holding it on stripped same with the wire from alternate to battery. And its bolt as well are stripped. I have tried sockets that grip better no good. What can I do as I can't tighten these down like they need to be?
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Tuesday, June 25th, 2019 AT 10:03 AM
Tiny
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So the bolt holding the wire on the solenoid is stripped? If so, you will need to replace these components because I don't think you can replace those bolts.
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Tuesday, June 25th, 2019 AT 5:57 PM
Tiny
VERONICA WIMMS
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Okay, so I got all the stripped bolts off and I replaced all the wiring from the alt to the starter the starter to the battery charged battery to full replaced everything that has melted used fiber fix on the EGR pipe for the hole it burnt cleaned the throttle body every things nice and snug and yet car tries to start, but wont turn over. Can it be the plugs maybe? If not what are your thoughts? Please
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Thursday, June 27th, 2019 AT 7:05 PM
Tiny
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It could be fouled plugs. I would pull the out and look at them just to find out.

Here is a guide that will help with hard starting. However, due to the damage that was done, I am not sure what else you could be dealing with. Once things like that happen, all bets are off.

As for fiber fix on EGR tubes, I am not sure that will hold up. The EGR takes exhaust gases and reuses them. These are hot and contain hydrocarbons and other combustion byproducts and more than likely will break this down. This is why most all EGR tubes and components are metal.

https://www.2carpros.com/articles/engine-cranks-excessively-before-starting
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Saturday, June 29th, 2019 AT 10:31 AM
Tiny
VERONICA WIMMS
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Well, I have changed the plugs and the crankshaft sensor as well and still no start. All wiring has been replaced that has burned or melted. Also the only things I have not are the EGR pipe camshaft and throttle body sensor and the last two were not physically damaged. I did check the fuel rail sensor and gas is getting to it, but still it will crank just not start. I am told possibly the fuel pump or its relay or the starter relay. Any thoughts or suggestions from here? The battery is good also. Could it possibly be the alternator or starter by chance?
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Sunday, June 30th, 2019 AT 12:35 AM

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