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Re: 04 LS DCCV wiring harness melted
The DCCV supply is probably on a 10A fuse. That's still sufficient current to melt an electrical connection if the connection is loose or corroded without the fuse blowing. I don't see any way that the engine coolant could possibly get hot enough to damage only the electrical connector area of the DCCV and not the rest of the DCCV housing or other components in contact with the cooling system, block, or head. The CHT sensor should have shut down cylinders long before the coolant could get that hot as well.
I would suspect that whatever is wrong with the DCCV electrical connection to cause the heat originally is still then, and probably compounding the issue is melted plastic on contacts as well.
Out of curiosity, how did you check the R-134a refrigerant to determine it is "good"?
-Rod
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