I've got a self-inflicted wound I'm trying to fix with the Focus, and I need help.
I'm using an Odyssey battery, and long story short, after changing which way the battery box was mounted, I accidentally hooked it up backwards for a second. One heart-stopping, welding-spark inducing second. I secured all of the positives to the negative terminal, then touched the grouped negatives to the positive. Doh! After the spark I yanked it away, and after a couple WTF seconds, I figured out what I'd done. It was enough current to spot weld several washers I was using as spacers together. My first thought was "oh ****, I hope I didn't fry the ECU!"
So, I checked all of the fuses and found nothing blown. Hopes were rising that I hadn't done anything catastrophic. Once I got the rest of the car together, I turned it over with the coil unplugged until I got oil pressure (took awhile, many 30 second cranks between batttery charges to fill an empty oil filter, turbo feed line and new cylinder head.) I was watching my oil pressure gauge and had nothing, finally realized the idiot light had gone out though. Plugged the coil back in and put in new plugs and it fired right up! Ran it for about a minute, then shut it down to check for leaks. However, none of my aftermarket gauges were working. I have them all run off of a terminal strip under the dash (I'll get to that in a second.)
Since then, the car cranks but doesn't start. Also, a bunch of odd stuff occurs, like not being able to turn off the wipers once they start. Turn the key off and back on and they're stopped, but turn them on at the switch and you can't turn them off, or oddly enough, hit the brakes and no brake lights come on, but the wipers start.
I know a lot of odd electrical behavior can be ground related, so I traced all of the grounds except the couple in the rear hatch, and nothing appears damaged. I was certain I was going to find some half-melted ground, having run the power to the grounds accidentally, but everything is clean and tight with no melted wires at the terminals anyway.
For my aftermarket gauges and radar/laser detectors, I'm tapping power off fuse position 52, an unused spot in my fuse panel (under dash "central junction box") normally used for heated seats, as my source for switched ignition power. When the ignition switch is turned on, it energizes a relay I added, which then powers the terminal strip for switched ignition power. This spot in the fuse box is only getting 7.2 volts, not enough to operate the relay. Using the Ford Wiring Diagrams book for the 2002 Focus, it seems everything labeled as coming from source 30S (voltage at all times, switched) is running at 7 volts or so. I'm having a tough time figuring out where exactly this power originates. The radio on fuse 41 is at 12.45V, with a source labeled as 75 (ignition switch in Accessory or Run), so it isn't everything that is effected, and makes me think the ignition switch is okay.
I've replaced all the relays under the hood in the Battery Junction Box, and all the relays in the CJB under the dash test good. There are two diodes that looks like a fuse in the BJB, as well as a fuse/diode labeled as F65/D3 that I haven't replaced as it tests good with the diode-testing function on my multimeter. Tracing stuff back, it seems that a lot of this stuff is controlled by the Generic Electronic Module (GEM), the box with five big plugs on it mounted in the ECU bracket. I had a spare from when I switched ECU's with the guy who had the turbo kit. My original GEM worked with the new ECU with no issues so I left it in, and the spare was originally used with my present ECU, so I switched the GEM, and there was no improvement.
The only thing I could think to do is reload my tune in the ECU, hoping that maybe the tune got zapped but not the ECU. Unfortunately, when I plug in my X2 and try to upload the tune, it does not recognize the ignition switch being on. My Innova scanner shows no codes.
Does anyone have any words of wisdom? Anything else I should check or try? Everything in the BJB that is labeled as hot at all times (30) has full battery voltage to it, I can't find where I'm losing half my power. I have a spare ignition switch, haven't changed that as the switch was not operated during that moment of switched power.
Again, I'm sorry to bother all of you with the results of my carelessness, but I'm at my wits end.