Headlights Killed Electrical
Thread Starter
3rd Gear
Joined: Jun 2014
Posts: 3
Likes: 0
Headlights Killed Electrical
Hi guys, new member here. I have a 1981 4-spd L81, been in a storage hangar with dirt floor last 6 years. The electrical was working fine, but dead starter. I could tow-start it just fine & get the engine running, everything worked except starter.
On the road driving, turned on headlights & the instant I did that, it killed EVERYTHING electrical. No dome lamp, no dummy lights with ignition, no clicking solenoids, nothing. New battery, tests fine. New starter & new alternator, both test fine.
Strangely, headlights still turn on, but that's it. I pulled all the visible fuses under the steering column & all look good.
One thicker orange wire coming into the fuse panel looks slightly melted & corroded connector, not sure if that was the same before or not.
I've read up in general forums, & consensus seems universally: headlights that kill all electrical = ground short somewhere, usually engine ground.
I've looked for engine ground wires but don't know where exactly to look. I have both Haynes manual & factory manual with electrical diagrams, but not sure what any of it means or how to diagnose this & find the short.
Any ideas?
On the road driving, turned on headlights & the instant I did that, it killed EVERYTHING electrical. No dome lamp, no dummy lights with ignition, no clicking solenoids, nothing. New battery, tests fine. New starter & new alternator, both test fine.
Strangely, headlights still turn on, but that's it. I pulled all the visible fuses under the steering column & all look good.
One thicker orange wire coming into the fuse panel looks slightly melted & corroded connector, not sure if that was the same before or not.
I've read up in general forums, & consensus seems universally: headlights that kill all electrical = ground short somewhere, usually engine ground.
I've looked for engine ground wires but don't know where exactly to look. I have both Haynes manual & factory manual with electrical diagrams, but not sure what any of it means or how to diagnose this & find the short.
Any ideas?
Last edited by charles9000; Jun 17, 2014 at 03:30 PM.
Le Mans Master
Joined: Oct 2010
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From: melbourne florida
2023 C3 of the Year Finalist - Modified
once you get that issue fixed contact this guy to upgrade your headlights, best modification i have made www.danielsternlighting.com/
Race Director
Joined: Apr 2009
Posts: 19,294
Likes: 2,753
From: Charlotte NC
ALSO...DO NOT FORGET that on your Corvette...there is a six terminal connector right at the back of the passenger valve cover that carries ALL the power to your system. I have seen these be bad and melt due to corrosion and poor contact....and I have numerous times...removed these wires out of the connectors and solder an shrink wrap them together and STOP this problem all together.
An AWFUL lot of current is going through this connection...and if the terminals are dirty or loose...you can have a problem....and also due to this connection is not water and dirt proof...it is easy for crap to get in this connection and begin the demise of it.
It is a BAD IDEA from GM and was only done to speed up assembly.
DUB
Thread Starter
3rd Gear
Joined: Jun 2014
Posts: 3
Likes: 0
Thanks for the quick feedback.
1.
I saw 2 fusible links going to the starter, both have bare wires & they're frayed slightly, but I have no idea how to see if they're melted or not. One has "16" stamped on it & the other "6", it's a slightly smaller plastic barrel.
1b.
What do I replace those fusible links with? The auto store only had a 14-gauge wire calling itself a fusible link, but it's a smaller gauge than the 2 barrel-wires going to the starter now. I don't want smaller wire, do I?
2.
I see an unconnected terminal at the rear passenger valve cover. I found a blue wire with a female spade connector that was unconnected that seems to fit. This terminal coming off the engine is not a spade connecter, but a round plunger looking thing with a flat head that fits that female spade connector. I don't see the 6-terminal connector but will look for it. This may be what killed the whole thing when I turned the headlights on, right?
I'll try to post pictures on here of what I'm looking at to be more descriptive. How do I attach photos?
1.
I saw 2 fusible links going to the starter, both have bare wires & they're frayed slightly, but I have no idea how to see if they're melted or not. One has "16" stamped on it & the other "6", it's a slightly smaller plastic barrel.
1b.
What do I replace those fusible links with? The auto store only had a 14-gauge wire calling itself a fusible link, but it's a smaller gauge than the 2 barrel-wires going to the starter now. I don't want smaller wire, do I?
2.
I see an unconnected terminal at the rear passenger valve cover. I found a blue wire with a female spade connector that was unconnected that seems to fit. This terminal coming off the engine is not a spade connecter, but a round plunger looking thing with a flat head that fits that female spade connector. I don't see the 6-terminal connector but will look for it. This may be what killed the whole thing when I turned the headlights on, right?
I'll try to post pictures on here of what I'm looking at to be more descriptive. How do I attach photos?
Last edited by charles9000; Jun 18, 2014 at 11:18 AM.
Race Director
Joined: Apr 2009
Posts: 19,294
Likes: 2,753
From: Charlotte NC
YES...photos are required.
The fusible links need to be a close as possible to the same length as what was installed and the correct gauge. You will loose the plastic portion of the wire where the fusible links are connected to the car wiring...but that happens sometimes.
DUB
The fusible links need to be a close as possible to the same length as what was installed and the correct gauge. You will loose the plastic portion of the wire where the fusible links are connected to the car wiring...but that happens sometimes.
DUB
Thread Starter
3rd Gear
Joined: Jun 2014
Posts: 3
Likes: 0
Questions 1-2 above still unanswered, so I'll make a #3 as well. If anyone knows, please help with the first 2 questions.
3.
I checked the 6-wire connector at rear passenger valve cover & it looks fine, nothing melted nor corroded.
4.
How do I attach photos?
5.
What if we forget the starter & fusible links for now, since I got the car running with a tow-start. Why did everything work fine until I turned on the headlights? I assume it's a ground short. Where exactly can I start looking to solve this electrical problem?
3.
I checked the 6-wire connector at rear passenger valve cover & it looks fine, nothing melted nor corroded.
4.
How do I attach photos?
5.
What if we forget the starter & fusible links for now, since I got the car running with a tow-start. Why did everything work fine until I turned on the headlights? I assume it's a ground short. Where exactly can I start looking to solve this electrical problem?
Last edited by charles9000; Jun 19, 2014 at 03:21 PM.
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