[searcherrr]

Status:
Very pissed about what else I found today. I know this is the shops fault too. Who in their right mind would route the main PCM wiring harness between the hot egr intake/exhaust pipe (driver side) and the rear (right engine) valve cover? On my 95, there is about 1" .. maybe 1.5" of space between those. Both get very very hot as we all know and the egr pipe hotter than hell. I had been noticing before that the main harness plastic protector holder, that routes right behind the rear fuel rail, had the little flaps in the upward unsecured position.

I was never able to see what the deal was till the intake plenum was off, but the flaps of the harness protector atop the engine could never go down because it just wasn't put back together properly. ALL of the bottom side of the main PCM wiring harness for about 4 inches is cinged/melted very badly. Most of the wires in the PCM wiring harness have merged together as a chunk of melted plastic and wire sheaths. Fearing what would happen if I tried to pick it all apart, I stopped after picking 1 wire ever so slowly with a screwdriver end and the wire sheath just peeled off.

Since I have no odd electrical behavior (I think) and think that the injectors and swapped ignition wires are going to resolve my issue, I'm betting that the metal core of the wires are not touching each other, but merely their outer coatings are merged. I put some liquid rubber all over the cinged area and puddied it back good. Then I wrapped some serious layers of electrical tape several times around it all.

After having to unplug everything (some stuff really hard to reach) I spent probably about 4-5 hours on just repairing the harness, getting it out of the wrong position, repositioning it, and stretching ma big azz to plug everything back in. Now its routed correctly, past the egr pipe (to the right of it) and away from the valve cover.

All I wanted to do today (yesterday now) was test the injectors before reassembling and then reassemble... only to find 1 more thing that some knuckleheads did wrong.

The sad sad sad thing about this is that if my injectors and spark wires in the right positions don't resolve my problem I can only assume that 1 or more of the wires where the main harness melted have to be touching and arcing out.