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Old 06-16-2012, 02:45 PM   #1 (permalink)
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Default Voltage variance between charging sys and fusebox

While the vehicle is running the charging system happily maintains 13.8-14.3 or so but the volt meter and fuse box for keyed runs around 11.8 or so, its causing all the instrumentation to be inaccurate from time to time. I grounded the engine to the chassis to the body to battery to the interior underdash. What could be causing this.

Was thinking to bring hot in (fused) from the battery and use a relay to introduce proper voltage to the rest of the system. I gotta ask first because there may be a simple fix and electricity is not my thing. Any ideas?

Thanks

Tony
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Old 06-16-2012, 04:32 PM   #2 (permalink)
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Loose or corroded connections or possibly a defective switch and/or relay - it's hard to say without knowing EXACTLY where you're making your measurements.
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Old 06-16-2012, 07:07 PM   #3 (permalink)
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Measurements for charging system taken at battery/alternator and consistent there. Grounds throughout vehicle are consistent and making a complete ground according to the ohm meter. All the connections I can view are clean.

The measurements taken inside the vehicle are at the fuse box or anywhere behind that dash you would expect full battery voltage. I have ground straps and jumpers on all major metal pieces so I figured there must be another variable I'm missing here. Maybe an electrical component I'm unaware of.

I should add that this vehicle has the 16v engine so the wiring is altered accordingly. Everything I see looks clean and intact. I'm stumped, tried all the things I know first like grounds and connection cleaning.

Tony
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Old 06-16-2012, 08:06 PM   #4 (permalink)
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Problem with a modified vehicle is that only the person who did the work knows what was done - what you consider "accordingly" and what I consider "accordingly" may not be the same - on the other hand - if I were looking at an unmodified vehicle, I can grab a schematic and know what to expect.

The power path on an unmolested Samurai flows from the battery positive through a fusible link to the fuse panel for unswitched 12V or through the ignition switch and then to the fuse panel for the switched 12V - you have a loose or corroded connection, or possibly a defective switch - and yes that's what I said earlier.

Get a schematic - Ack's FAQ should have - and start at one end - measure the voltage and find out where the drop occurs (between where & where) and that will tell you where the problem lies - if it's the switched +12V - measure the voltage where it enters the switch and where it exits - if it's not within millivolts then the switch is the problem.

If the voltage is low going into the switch, the problem is between the battery & the switch - if the voltage is good going into the switch and coming out of the switch, the problem is between the switch and the fuse panel.

Get the idea?

Oh - if the wiring is not as on the schematic (meaning it's been modified or a Sidekick loom has been used) then those instructions will probably lead you up the gum tree.
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Last edited by fordem; 06-16-2012 at 08:36 PM.
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