Its quite clear in the Rave PDF. This is the page I've been looking at....
http://www.mydocz.com/Landie/KSeriesStartingCircuit.jpg
You'll need to zoom in on this image and the quality isn't good, so best go to the Rave PDF directly.
The only complex bits it goes though are the fuse box and relay box housings. Other than that its wire.
I'm still thinking its corrosion/earth around fuse F1, or the wire from there to relay, or possibly the relay is caput. Its got to be one of those because that feed does not go past the relay when the ignition is not at crank.
Hi Stebo, any news? I was just about to post about some experience somewhat similar on a Ford a few years back. Same issues to that. Silly me (never again!), was trying to tighten the alternator bracket mount without having d/c the negative terminal on the battery.. what happens? My arm slips and a skinny part of a metal screwdriver falls in and comes in to contact with the internals of the alternator, a massive spark is then seen! The symptoms that you have followed. It wouldn't start and kept on blowing one particular fuse. I would replace it, it would blow it again. Turned out to the a relay that had gone. Replaced the relay and all was fine. Given it had resulted in sparking, i removed that alternator and put in a known working one. The electrical system is usually set up so that a relay will usually knacker itself out rather than major components being affected. That was on a 99 Ford Festiva though. We can forget about this idea as you said you've removed the engine compartment relays box with one which works fine from another Hippo....
I have replaced the ignition switch and the immobiliser ring today but fuse is still blowing. Here is a list of the things ive replaced. Let me know if ive missed anything please.
Starter motor (twice)
Battery
Ignition switch
Immobiliser ring
Relay box
Fuse box
Starter to battery wire
Starter to relay wire
Earth from battery
Cleaned connections
As you're happy jumping the starter solenoid. Disconnect the wire from Fuse F1 to Starter Relay at the fuse - this will take the relay and wire out of the equation. Then Jump the solenoid from battery.
If it still blows the problem must be in the fuse box (presumably!) - not further down the line in the wires/Relay.
I think its time to get an auto electrician on it though.
christ mate no wonder ur going up the wall
trying to rack my brain in what it could be
I don't know if looking in the owners manual or haynes and pulling every fuse out u don't need for the car to start if it would help in any way
would be a great start to just allow the car to start without the fuse blowing
wonder if a sensor could do this
but that's just clutching at straws
will have another look through the net and see if i can see anyone else having this problem
trouble is also car wiring techs could be expensive to resolve , so after the fuse has blown do u then replace the starter motor fuse with the engine running , must be a royal pain and feel for u mate
Heads up my arse mate.
When the fuse blows i just wait until i need to start it again then either replace the fuse or bump start it.
u didn't happen to buy ur starter motors from the same place , could it be a bad batch , ????
shame u wernt nearer to me as I would have helped u all I can
two heads better than one
so could have gone through it with a fresh set of eyes
but maybe it may be time for an auto electrician but agree there expensive
just feel sorry for u mate and wish I could help u more as it must be very frustrating
I know I'm clutching at straws here but
would unplugging all the sensors, including the lamba one, spraying both plugs with electrical cleaning spray and reconnecting them work ??
also do the same with the 12 v starter motor lead, alternator plug
everything that could be unplugged and sprayed then reconnected
know it has a warning of never unplugging the main ecu as it can cause damage
had another thought , inside ur ecu box do u have a fan in there , as I wondered if it could spray water inside the box and over something and pop a fuse
just clutching at straws
has someone got a diagnostic machine near u , would it tell u anything
also spraying ur abs sensors
did u fix ur rear brake light , lol
will be interesting to see how it goes and if we need to break u out of the nearest nut house where you've lost all ur sanity