Please help, EGI Comp fuse keeps blowing, main relay keeps melting
 

like the topic says, the egi comp fuse blew, and 2 of the wires on my main relay melted(the rubber, not the whole wire), so they were shorting together... this happened when iw as driving thru san bernadino cali on the way to TX where i am now... if i don't get any solid ideas by the morning i am calling Rotary Performance in garland... let the pros fix it... in San Bernadino i had to have an automotive electrician fix it, and it got me all the way from there to here... he replaced the wire off the EGI comp fuse that melted, and replaced the main relay with a much newer lookign one, and the part numbers matched so i know its the right one... each time this has happened its been at normal cruising speed on the highway... this time i was able to fix it enough to drive the car the 20 minutes it took to get home, i took the main relay out and wrapped the wires with a lot of cellafane from the flowers i bought my gf, wrapped the relay part of it in a plastic bag, hooked it back up, and put a penny in the fuses place...before i tried the penny i took the 30 amp fuse from the retractor out and put it in the place of the EGI comp fuse, and it ran for about 30 seconds then when i gave it some gas to get off the side of the highway, blew that one too... so i put the penny in and it got me all the way home no problems, no smell of smoke... any ideas at all? if not i'll just take it to RP probly tomorrow, they are only bout half an hour from me

Well, let us know what they find!!

Let them look at it - electrical problems are a nightmare.  If you have no clue right now, it's best to let the experts look at it.

That fuse powers the fuel injectors and most of the 12V sensors on the engine.  The short will most likely be on the engine.


-Ted

heres pics of what is happening to the main relay... i called Rotary Performance and they said they don't work on 1st and 2nd gens much, and referred me to 2 other shops, the closest doesn't open till noon

http://www.uploadit.org/Elysian893/Main-Relay-1.JPG
http://www.uploadit.org/Elysian893/Main-Relay-2.JPG

and yes my main relay's housing is off, i took it off to check to see the relay was ok, which internally it is

https://www.rx7club.com/forum/attach...postid=1398836https://www.rx7club.com/forum/attach...postid=1398836

You can look at the img above and tell that it's the WL and the BW wire on the HARNESS side of the relay that are causing the short. And like the man said.....its the BW wire that feeds all the solenoids.

The first place I'd look is around the ACV and the two solenoids that are connected to it. Those would be the Split Air and Port Air solenoids. See if the plugs or harness for them has fallen down and touched the turbo/exaust etc.

The places this BW wire goes to are the two items above and: Power Steering Sw....ASV.....PRCV....BAC...EGR...AIRBYPASS SOLENOID....TCV SOLENOID.....SWITCHING SOLENOID....RELIEF SOLENOID....PRESSURE SENSOR.....ATP SENSOR.....KNOCK CONTROL SENSOR

You can't rule anything out, but the least likely would be the ATP sensor, the Pressure sensor and Knock Control sensor.

You NEED to look at each plug on these sensors and see if one of them has a FRIED look. The wire on each sensor plug, that you look at, will be each and everytime a BLACK/WHITE wire. Like I said, start with the Port Air solenoid and the Split Air solenoid.

https://www.rx7club.com/forum/attach...postid=1451627https://www.rx7club.com/forum/attach...postid=1451627

wow that looks like a fire waiting to happen. make sure you get that fixed asap man. you're lucky, we dont have any rotary mechanics around here. closest one that i know of is rotaryresurrection down in tennessee

i figured out the issue... a wire on the passenger side that goes under the intake manifold, around the intercooler bracket, behind the alternator, down under the MAF, into the main wire bundle, melted, was just bare wire all the way thru... so i pulled the Intake manifold and turbo off, and proceeded to removing this wire... it wasn't hooked to anything, it just fell into the exhaust manifold and grounded out.... and melted the whole wire when it grounded.... so i totally removed the wire from the car... it went into another set of wires via a coupler, and those wires were fine, not melted... so i think that should fix the issue, if it doesn't happen again then it did! and the main relay is still fine, in fact i got my electrical tape out and taped it all up, its way fixed now

Good job!


-Ted

Good for you! :) I would still be looking... :scratch: ;)