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Burnt wire

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Discussion starter · #21 ·
Engine out. I still haven't found out what year model my replacement motor is. It is a sonata motor, year unknown though. It does have a return line fuel rail, so no issue there.. I had to swap the coil packs, different connector. So far thats all I have found. I'll get elbow deep in there this weekend when i go back in with the other engine. I do know I took way to much stuff off the engine to remove it. When it goes back in the only real "part" that will be reattached is the ac compressor. Now I can get in there and get a good look at my wiring. My starter hot wire looks like it possibly has been rubbing hard against the transmission and may have been grounding off and on, not to mention not really tight on the starter.
 
Discussion starter · #22 · (Edited)
Burnt wire found!

I got in there and started cutting off tape and peeling stuff back and here is what I found:

Image

It ended up at this plug. This is the connector for the coil pack. It has a several larger wires made up in a cable similar to a coaxial cable. The grounding shield is what this small black ground wire attaches to.
Image

This is the termination to the shield
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I don't what or why it happened, I guess maybe the engine ground became bad? who knows. I think the real issue was this darn wire had burned through multiple wires on it way to its exit of the harness. Burned clean through several wires taking them to ground. I am attaching two separate wires at this location and exiting the harness on the spot. One ground to engine, one to the front clip. Gotta get this mess taped back up so I can get on with it. I am also going to have a good look at the relay box and see how that hot mess is grounded. I know this power comes from that location.
 
Discussion starter · #25 ·
Solved!!!!!!!!!!!!!

Burnt wire solved. I have 12 volts from block to battery ground. I got a hot wire touching the frame or engine somewhere. It melted the same wire again 20 minutes into the shake down drive this evening. Suddenly the car got hot. I got off to the side and found the headlights being turned off would put the temp gauge back to normal range. Headlights on, temp gauge buries
Got her home and found the car was NOT hot with OBD. :facepalm: Well I got all day tomorrow to find it. Real bummer, car runs like a champ. Matter of fact it has never ran this good. I get this sorted and the worlds gonna turn..
 
Discussion starter · #26 ·
Took the battery ground to the block and that was that. I kept the battery to frame ground as well. Everything functions properly. I replaced the crappy grounding strap to the firewall and replaced it with a battery ground cable as well. I searched for 4 hrs and found no "hot" wire to the chassis. I really cannot figure out where the voltage was coming from. I do know it was trying to go to ground through the coil pack ground wire. I followed my daughter to work (23 miles) I told her to turn on everything in the car on the way there. When we got there I checked the small ground wire as well as the battery cables to see if anything had gotten hot but nothing had. She said the temp ran perfect straight up to less than half all the way. Victory.
 
#27 ·
ibbw said:
Engine out. I still haven't found out what year model my replacement motor is. It is a sonata motor, year unknown though. It does have a return line fuel rail, so no issue there.. I had to swap the coil packs, different connector. So far thats all I have found. I'll get elbow deep in there this weekend when i go back in with the other engine. I do know I took way to much stuff off the engine to remove it. When it goes back in the only real "part" that will be reattached is the ac compressor. Now I can get in there and get a good look at my wiring. My starter hot wire looks like it possibly has been rubbing hard against the transmission and may have been grounding off and on, not to mention not really tight on the starter.
Click to expand...
I am doing the exact same swap and my troubles are in the coil pack. ever since ive dropped the 04 sonata engine in my 03 tiburon, v6, i havent gotten any spark to the spark plugs. at first, i thought id gave to swapp the coil packs too because the connection is different to the main harness but then i figured and have been told that i could just use the tiburon coils. so I bought a new coil pack because that would tell me if the coils ive been using before are bad, but that isnt the problem. did you just drop the motor in without changing an ecu? did you change the crank or cam sensors?
 
Discussion starter · #28 ·
You are Positive you are not getting spark. Pull a plug boot stick a plug in and lay it down on the motor and turn the engine over, it should be obvious. I would do this to make sure you do/do not have fire. There are several other things that could be causing it so don't be too sure that's the coils that are the issue. I am not positive but I would think you should have 12 volts coming to the coils with key in the run position at the coil pack connector.

I used my intake, throttle body,fuel rail, fuel regulator, injectors, coils, crank sensor, starter and purge valve. That's it. Car started and ran flawlessly. Make double sure ALL connectors are plugged in and that your engine grounds are solid. I added a battery negative post to block ground wire. Battery post to frame, check it, mine was rotten. Engine to fire wall, check it. Grounding kit is inexpensive or just use copper battery grounds like I did.

Did you research your vin to be positive what it came out of?
 
#29 ·
After doing a valve job I missed the main ground cable to the intake bolted to the left passenger firewall. Burnt the coil pack wire and popped a 20 amp fuse under the dash. Save yourself some trouble and hook the ground wire up prior to trying to start the vehicle after any major repairs.

To avoid risking your main wire harness solder the coil ground wire to the shielding of the four wire cable That plugs into the coil pack. Use a sharp knife to scrape away the goo until you get clean copper. Run the wire direct from the shielding of the coil wire to the coil pack frame and not back through the main harness.

Yea Ha lesson learned.

Thanks for all the info about went mad until I picked up a 5 buck pic light to check the fuses
.
 
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