2002 R53; Just replaced engine.
I am getting terrible sparks when trying to connect the battery and everything is consequently dead.
The engine was taken out by someone else so my guess is the starter connections are in question.

1. How many wires should connect the the starter?
- I have two large cables and one small one. The two are a cable from the battery positive, connected to the same post as a cable from the positive jump start stud under hood with the last cable being connected to the starter solenoid.

2. The starter shield is NOT shorting out on the positive studs.
What could this be?
I used a DMM and sure enough my pos and neg are shorted (likely misconnected) somewhere.
Ideas?
Thanks.

 

 

The battery has been full charged out of the car and upon installation (put positive on first, then negative) as soon as the negative just touches the battery I get HUGE nasty sparks.

I took a DMM and confirmed the positive jump start stud under hood is shorted (has continuity) to the Negative frame rail ground.

I suspect the problem is a connection.
I "installed" my engine (someone else removed it) hence it is potential that a cable is hooked up wrong.

Therefore, how many wires connect to the starter and where?
I placed two cables (one from battery and one from jump start stud) to the a single stud on the starter. A third smaller wire to the starter solenoid.

No, I do not have a pdf of the battery cable routing so if anyone has that, it would help me.

I am basically making connections blind.

 

I'd start by looking here. They have intricate wiring diagrams even if though the site navigation is a bit strange or arcane it is complete. https://www.newtis.info/tisv2/a/en/r53-cooper-s-hat/
-Mike

 

 

So likely the other wire is ground. Does anyone have documentation or sketch?

So, I assume battery positive goes to starter and then solenoid wire. The third wire has to be a ground. Only question though, it is a rather short cable (about 1.5 feet long). I routed it from the jump start (pos stud) to the starter.

A drawing or sketch would be ideal and I can follow it through.

 

I am using realoem (website) to help me identify. The guy that pulled the engine tore everything out including the engine harness. If anyone has a sketch or their own diagram, feel free to post. It sounds I have cable connected where it shouldn't be.

 

 

There's a photo on Pelican's clutch replacement tutorial which shows the starter wired properly.
Looks like the short wire from starter motor to solenoid is at the right of photo.

Hope this helps.

 

Yes, disconnecting the 1.5' long cable does work. Just need to figure out where it is supposed to go. (From to). I assume it is a ground.

 

 

Got it.
It was the small wire on the starter contacting the starter shield.