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post #1 of (permalink) Old 08-17-2009, 01:24 PM Thread Starter
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blowing ignition fuse???

So driving down the road yesterday, Zuk dies on me, find ignition fuse blown, replace it, make it another 50 feet down road and it blows it again. Get it towed home and every time I try to start it, it blows the fuse, so I disconnect the ecm turn key forward without trying to start and fuse pops, reconnect ecm and fuse pops as soon as key is turned forward without trying to start?
Im not real good with electrical can you guys offer suggestions as to where to start hunting to fix this problem?

thanks a bunch

96 Cherokee Country
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post #2 of (permalink) Old 08-18-2009, 09:09 PM
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ignition fuse blows...

I had this EXACT problem one day while delivering pizza!


I dug up a wiring diagram (several of them are at Ack's FAQ - see signature) and traced the ignition circuit.

I unplugged EVERYTHING in that circuit, installed a fresh fuse, then tried the ignition. Fuse did not pop.

Then, one by one, I reconnected each device to the circuit and then turned on the ignition.

The fuse blew when I connected the ignitor circuit (the connector that hangs off the distributor). Problem successfully diagnosed!

A quick trip to the local pick-n-pull to snag onto a Samurai distributor for $20 and Bam! I'm back in business!

You can order a new ignitor circuit from places like Rock Auto, but - at over $250 - you'll want to check out the salvage yards, pick-n-pulls or samurai owners on the forums first.

Natually, something else might be going wrong, but that's how I would troubleshoot the problem.

I hope that this helps!

Ack
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nearly 837 searchable links to Suzuki/Geo modding and maintenence info - including the Tracker FSM Project!
'88 "SJ-416 Samurai"
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post #3 of (permalink) Old 08-18-2009, 09:20 PM Thread Starter
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Thanks Ack, yes I hit your site and grabbed the wiring diagrams, thanks for the tip on how to narrow the problem, I knew there would be a better way to do it than my way of randomly looking everywhere for a frayed wire or such.

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post #4 of (permalink) Old 08-21-2009, 02:08 PM Thread Starter
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WooHoo, problem solved

disconnected everything, fuse would not blow, so 1 by 1 started reconnecting (only turning key forward at this point without trying to start the zuk) got everything reconnected and fuse was still good, started it up and it ran for about 10 seconds and then blew fuse again, so then I just started looking everywhere under the hood for anything peculiar. I have a GM alternator conversion, 3 wire type, and 1 of the wires had worked itself loose and was making contact with the body of the Alt., damn im happy thats all it was instead of having to inspect all of the wires

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