Engine Swap Electrical Problems

[Newell_89]

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.

[93LT]

How much of the truck did you dismantle to do the engine swap?

[Newell_89]

Originally Posted by 93LT

How much of the truck did you dismantle to do the engine swap?

I took off most of the front end like hood, fenders, inner fenders rad support. I have the bed off too. Alot was rotted so I replaced.

[93LT]

I think your best bet is to see if you can find someone to bring over their pickup, 2 or 4wd, and verify the wiring and grounds. Your lights sound like a ground issue.

[Newell_89]

Originally Posted by 93LT

I think your best bet is to see if you can find someone to bring over their pickup, 2 or 4wd, and verify the wiring and grounds. Your lights sound like a ground issue.

Yeah eh. I hate to admit defeat but that sounds like a good idea. I don't know anyone around me with an 88-98 that's not a vortec. I'll go to a dealership that I know has some tbi trucks and pretend to be intrested in buying.

[bigj-dog]

Had a similar problem but with a little newer Chev, we had to replace the front clip because of a kamikaze deer attack and somehow the ground for the front lights and and a bunch of other stuff never got hooked back up, and caused serious problems. It was located just below the grill on the front of the drivers frame rail front horn.