Caliber350

02 Z06

So, I'm diagnosing a hard starting problem. I remove the battery and tray, and here's what I found: The red/white 8 gauge wire marked "ALT TO STARTER" is completely eaten through from battery acid (before I bought the car). The cable starts at the B+ on the fuse block (photo #6) then merges into the wire harness at the rear of the engine (photo #4)

Does it connect to the starter at all?
If so does it go directly to the starter, then the alternator?

[I know it eventually leads to the alternator because there's continuity between the frayed end (where the acid ate through it) and the alternator.]

BTW, this car is wired for an aftermarket sound system. There's a fat zero gauge cable that directly connects the positive battery terminal and alternator (photo #5). There's also a cable (8 gauge or slightly thicker) directly connecting the starter and positive battery terminal.

So, can I just disconnect the damaged 8 gauge cable at the alternator (alternator to fuse-block) (photo #5) since the alternator's already connected directly to the battery via the zero gauge? Or does it serve some other purpose?

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Caliber350

anyone???

dgrant3830

Send a PM to Bill Curlee or Lucky131969. They can best advise you

Caliber350

Thanks. I PMed them both. Hope someone'll chime in here...

lucky131969

What a mess. I can see how extensive the corrosion is below the battery tray. Your primary concern should be, to remove the PCM and TAC, bag the connectors, and thoroughly treat everything with a water/baking soda solution immediately. Repeat the process until all the acid is neutralized, and rinse. Allow to dry, then prime/paint the surfaces to prevent further corrosion. Careful inspection of the PCM and TAC should be performed as well. Your vacuum lines are almost certainly trashed, so those will need to be replaced.

With regard to the wiring. I would pull out all that goofy crap, and return the car to stock. No sense in trying to make good, of someone's mess. I'm guessing there is no fuse between the alternator and starter anymore. You'll have to inspect the starter, to see what's left down there. There should be three wires connected at the large post of the starter:

1) Rust - fusible link to alternator
2) Gray - fusible link to alternator
3) Red - direct to the battery.

lionelhutz

My guess would be that the stock charging wire was re-routed from the starter solenoid and connected to that fuse block post instead. Stock, there is only supposed to be a single wire going to the battery positive post connector on that lug.