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Engine Swap Electrical Problems
Alright so i have a 1995 Chevrolet C/K1500 4x4, originally equipped with a 305C.I. Bad compression and burning oil, inspired my to swap out that worn out 305 with a former 350 I bored and stroked to a 383. The engine is in the truck now and all the connections to all the sensors are made, as well as all the grounds as far as I know. I have the block grounded to the frame, and the fuel pump grounded to the frame too. I have a brand new bench tested starter bolted up and connected to the battery, and all my fuses and relays have been tested and are good.
So on to the problem.. ***With out the key in the ignition*** As soon as I connect the battery the running lights turn on and the fuel pump cycles on and of momentarily as if the ignition was in the "on" position. However if I got into the cab while the battery is connected still and pull the headlight relay and put it back in; the lights stay off until I turn the headlights on by switching them on, but when i switch them "off" again the running lights remain on.
***Key in the ignition*** The lights stay on, horn doesn’t work, (lets out a wimpy sound), wipers don’t work, radio works fine, interior lights are fine, dash lights work. but when i go to start it the solenoid engages the drive gear to the flex plate but the starter motor does not even make an attempt to spin(and no my engine isn’t seized), I figured I had a bad ground some where so i found all the grounds that i have connected and cleaned the contact surfaces to ensure good ground. As I was pulling off a ground wire off one of the water neck studs (the single wire Black w/ white stripe) a spark jumped and it gave off 9 Volts! I thought id find a short in the harness some where but I traced the wire rite up to the fire wall but it’s in great condition?
Too many things are going wrong from a formally perfectly functioning electrical system. I can’t figure this out for the life of me. It’s driving me crazy. Anyways I appreciate ANY input you guys have towards this problem or problems, depending how you want to look at it.
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