I have a really weird problem with my EVO IX MR

- I got 4 batterie metl down...

Everytime i changed it, the car runs ok, i turn it off, turn it on, and i cant do more than 1 miles then the car car turn off.

Everytime, when I open the hood, the battery is really hot, also the negative wire too.

Its a bushur mini--battery but I also tried with a normal battery and it's the same thing, so it's not the battery

The alternator voltage is A-1, I also tried without the alternator plugged in, samething...

We check the stater, everything is A-1 too

I rellay dont know where to check, and my mechanic is really confused too, he's really good in electricity but we facing a weird problem

Please help me !!!

 

silly question, but have you been reversing the polarity of your terminals by mistake? Either the cables or the terminals on the buschur battery?

 

If the ground wire is hot, then it has too much resistance. Replace it with a bigger gauge wire, and make sure the connections at both ends are good. Once a wire gets hot like you're describing, the strands melt together and resistance goes up.

What's happening is that your car is charging the battery, but because of the high resistance of the ground wire the battery is heating up.

Have you made sure your voltage regulator is functioning properly?

 

i was going to mention the voltage regulator, but he stated that the same problem happens with the alternator disconnected so thought mayyybe not.

but what you say makes perfect sense. is this a common problem with mini batteries? OP did you use the stock ground wire or an aftermarket relocation kit wire? If it is the latter, you might have used a lesser gauge wire.

 

we try to put another ground with the old one in place, same thing...

 

and what i didnt said, the car has the same setup for more than one year and everything was woriking welll....

It becawe worst slowly before adding a grimmspped boost controller and retuning....

 

I would check what was stated above. Make sure the ground cable at the battery and to its ending ground point are clean. If there is any green color on the cable wires or oxidation/rust where it bolts to chassis or trans clean it up.

Typically if the ground was so badly corroded that car wouldnt even start. Also can you get voltage readings for us as in 14.xx and some pics of your battery setup.

 

inspect and clean all grounds

 

Could start with CHECKING the resistance on the ground circuit... I've seen tuned evo's with small batteries do exactly what someone said a few posts ago... melt the strands. If you are generating heat it means there's a load. That can be high resistance on a dedicated ground, a soft short or a backfeed. Normal electrical loading won't do that so that eliminates your generic ignition off draw, what you have is abnormal. You mentioned an electronic boost controller that marked the beginning of the problem... i'd start looking around that area.

 

1. Are you actually melting through the ground wire or is it just hot? Is the protective covering melting?
2. Are you running any type of amplifier for your radio?
3. Just going to a smaller battery using the stock battery connections should have no effect.

4. Check your connections for the ground wire and make sure the wire has not been cut, both of these could increase the resistance.

 

-1 The ground wire become really hot but dont melt. Just the battery melt.

-2 No amplifier, stock radio

-3 ok, it was like that when i buy the car, it already have the mini battery

 

And I have a FLir infra-red camera for my job, should that be usefull to find the problem ?

 

The battery melts? Picture please! Now this sounds interesting. So, you have replaced it how many times? The ground cable should get hot, current is flowing through it.

You can experience this with a vacuum, feel the cord before the plug it in to the wall. Run it for 5 minutes and the cable will get hot, but not enough to melt it. So, its normal.

If you were to put a smaller gauge ground wire on, then it would work as a fusible link. Meaning that it would blow or burn through once it reached the point were to much current is flowing through it and burns up. Same principle as a fuse.

Post a pic of the battery and installation.

 

Do some voltage testing. Maybe your alternator is over charging due to bad voltage regulator

 

I assumed they had already checked ground resistances, but I shouldn't have assumed anything

After reading the original post a 2nd time... I need to make sure I understand the problem.

You start the car, it runs fine. You turn the car off, restart the car, and drive less than 1 mile. Car dies. You open hood, battery is melted? Correct?

Also, you managed to melt a battery while the alternator was unplugged?! How did you unplug the alternator? If the alternator truly was removed the circuit, that means the only electricity in the car was coming from the battery. That means it melted itself... The only things I can imagine causing that are either serious backfeed or reversed polarity somewhere.

I'd take the car to a shop that specializes in electrical work.

Keep in mind that your ground wire should NOT get hot enough to melt EVER. Yes, it will get warm but it should not EVER be too hot to touch and it should NEVER EVER EVER melt or get hot enough to fuse the strands together and become stiff. The way ^^ is worded might imply to n00bs that it's OK for a ground to get that hot