A/C compressor replacement and short circuit

[patriceboivin]

A local repair shop here replaced the old A/C compressor with a refurbished one from Japan. Worked great.
However as I left their lot around their closing time, I glanced at the Voltmeter and noticed that it wasn't between 12V and 14V anymore, it was barely at 12V. Usually it stays near 14V.

Drove away, about 4 minutes from the repair shop the ventilation fan stopped, the radio shut off, the clock as well. I thought maybe I pressed too many buttons? When I pressed the Auto button for ventilation I could hear a "click" but the fan just wouldn't run. I was testing the A/C by switching it between recycling and fresh air, different modes, front and back... Then at the stop light I noticed the sun roof motor wouldn't run, neither did the motor for the crystal roof shades. Same thing for the sun roof: I think I can hear a "click" but no motor. Voltmeter now was below 12V, going toward 11V.

Drove home like that. Told my wife I think the Delica may have a short.

Next morning, went to work, except now the voltmeter was at just below 11V. At lunch I dropped by the repair shop and told them I think I have a short because the voltmeter is staying below where it usually is, I suggested dropping off the Delica on Monday morning. I made sure the A/C and ventilation fan settings were all set to off. At the end of the day, drove back home, now it was barely at 11V. I replaced ALL the fuses with new ones in the engine bay and in the box under the steering wheel. (new fuses that light up when they fail) If there are other fuses hidden elsewhere please let me know.

In the evening we decided to drive to Halifax to eat supper at a pub, as we drove back across the harbour bridge I noticed the voltmeter was now definitely below 11V, closer to 10.5V... on the way back by the time we reached Main Street, 9V... Funny things start to happen when your voltage drops that low: the RPM meter would drop to zero, then back up to normal, then zero again. the odometer flashed a few times. At the corner of my street, 8V. RPM, spedometer stayed at zero. I didn't test last night but I am pretty sure the front lights wouldn't come on. Managed to make it to my driveway.
Drove the Honda Fit this morning.

I suspect there is a short circuit somewhere. Given the symptoms and the work they did, any ideas where that short might be? I am guessing it could be on the passenger side in the engine bay or behind the glove box somewhere. To replace the compressor and test the A/C would they have disturbed wires elsewhere?

I did ask them to see if there was another unused plug on the passenger side right behind the grille, like the one on the driver's side. I forgot to ask them if they found one but they were probably in there as well.

I wish I had a lift, I could really get in there and inspect everything myself. I wonder if I can rent time on someone's lift, maybe at a small service station or something.

[Big-Bird]

Electric motors use lots of amps to operate and a weak/low battery charge would only yield a click as the amps would drop drastically. What you have described would make me check for a loose belt on the alternator which would serioiusy affect amp/voltage output. To get the AC compressor off they may have loosened the alternator belt. When voltage/amperage drops below a certain point the relays will click but they won't stay active.....click click click.....sound familiar??? you should have about 1" of slack in either direction on the alternator belt which is easy to check by pulling/pushing on that belt by hand. A low amount of effort is needed to verify proper tension.

Put your batteries on a charger overnight. Get your charging system checked the next day at a Part Source who can do this test for free!!!! And in 5min you will know if you have a battery or alternator issue or perhaps both. And of you did have a loose belt you have the added benefit of knowing how healthy your charging system is.

Do the cheap stuff first, then dive in to assess replacement items as needed. And if your alternator is the source it can be rebuilt in a few days by any alternator shop. The parts for these are used in many common brands and the rebuild cost won't break the bank like a new unit would.

Cheers and good luck.

[patriceboivin]

I let the van run idle yesterday for about an hour, that brought the voltage back up to 10V but it never went above that.

Earlier this evening I drove it back to the repair shop, they will take a look at it tomorrow.

[patriceboivin]

They found the short -- the plastic on a wire behind the alternator wore out, causing a short.

Three of the larger fuses had to be replaced as well.

All is good again.

Now I'm back to thinking about how to hook up the H4 fog lights I got from Japan.
Did not find anything online on how to do this and the Delica wiring diagrams don't mention fog lights even though they were a dealer option from the very beginning.