I think I may have found what has been causing my electrical problem - Ford Powerstroke Diesel Forum
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Old 08-23-2013, 06:25 AM
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I think I may have found what has been causing my electrical problem

I've been getting all 8 glowplug codes on startup, my battery voltage on my Insight CTS has been wildly fluctuating, sometimes even dropping in the low 12s and high 11s. But when I hook up a voltmeter I'll get a good voltage at the alternator 13.8-14 no matter what and at the batteries will just be a bit lower than that at 13.3-13.5 and only around 13 on my Insight, but it jumps all over the place varying 1 to 1.5 volts.

So I saw a cable going from the positive side of the passenger battery and noticed it had a small chafe on it. I wiggled it around and noticed the voltage on the batteries jump up! So I pushed it in and the battery voltage jumped up to nearly exactly what the alternator voltage was and my Insight was showing only .1 volts under that and it was stable.

Apparently this cable is coming from the alternator? Is it something that I will be able to fix myself or is it something inexpensive and easy to replace?

Last edited by Jingoist; 08-23-2013 at 06:32 AM.
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Old 08-23-2013, 08:06 AM
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Changing a cable out is not hard you'll be fine. how bad is the rub or chafing if it's just the insulation tape it up good and add a piece of rubber to stop it from getting worse. nice catch by the way.
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Old 08-23-2013, 05:43 PM
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Quote:
Originally Posted by poorboy1964 View Post
Changing a cable out is not hard you'll be fine. how bad is the rub or chafing if it's just the insulation tape it up good and add a piece of rubber to stop it from getting worse. nice catch by the way.
I wrapped it up and while the overall voltage has certainly increased, but the voltage being shown on my CTS still bounces around a bit, though only by .2-3 volts and the it is only about .2 lower than at the battery.

The chaffing is right before the part that attaches to the battery, so I'll likely just chop and the end off and put a new connector on and hopefully that will make it much more stable.

Such a stupid thing to be causing so many problems. I was just about to go buy another GPCM and alternator.....
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Old 08-27-2013, 04:03 PM
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in the long run, I'd say get new cable one size larger. if it's causing a fluctuation, the conductor is badly damaged. just resealing(as suggested) it is not going to fix that
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