I've got a '93 with stock twins and freed up exhaust (center section, no cats, and exhaust), chiped ECU, intake, EGR disabled, and profec-b.

Just installed Koyo radiator, new temp sensor in filler neck, and removed Air Pump (new pulleys).

Everything is back together and car starts / idles good (if a little high - 1,200RPM).

But now when I turn on my headlights the car dies! The lights do not even try to raise up, it just goes dead.

Here's what I've tried:
- Tested Battery (good charge, holds charge)
- Removed the Positive lead from battery with car running (kept running just fine while removed)
- Turned all accessories / lights on (radio, heater, haz lights, parking lights, dome lights) all with out killing the engine
- Tried turning on headlights and then turning them off again quickly, but the car still instantly dies (does not even try to stay running)

Now the button to raise the headlights will work with out killing the engine, but they only seem to raise about half-way. If I give the driver side light a little tap it will raise the rest of the way!?!? With them raised up, when I turn on the headlights it's the same thing, engine instantly dies.

Now when installing the radiator, the wireing harness got moved around alot and ofcourse everything is very brittle seeming. I am assuming (based on other "headlights killing engine posts") it is a electrical short of some kind.

Any ideas what this could be would be appreciated, or any tips on tracking down a short in this area would be great too!

Thanks in advance!

 

get the wiring diagram and start tracing/testing wires. ;0
John

 

I'd also make sure you didn't disconnect a major ground wire somewhere. The wiring diagram has ground locations, double-check all of them.

It will probably be a pain to find the culprit, but it's probably pretty simple when you find where the problem is.

Dale

 

Thanks, so it sounds to you for sure like a electrical short then?

I can get the intake, IC, air hoses out pretty easy but I hate to have to remove the radiator again...

Do you know of any ground points that would require me to remove more than this to inspect?

Thanks

 

did you ever figure what caused the short when the headlights are on? My car is having the same issue right now? and i can not figure it out! grounds check, no broken wires, traced everything in the entire headlight assembly, to relay, combination switch to lights. Its an unknown issue! any help would be awesome!

 

I have the same issue. Did you ever figure it out?

 

If it stumbles and dies its most likely tune related or a faulty electric load sensing unit (rare). If it dies instantly I would look at the wiring under the headlights. The body electrical harness runs behind there and I bet something is moving/rubbing.