99 IDM Wire Chafing on Valve Cover

5794 Views 8 Replies 5 Participants Last post by Andrew G, Sep 11, 2011

Lee157

Discussion Starter · Sep 10, 2011 (Edited)

Hi guys figured I'd post these pics since I never found any when researching

Valve cover

Wire Harness

I found this spot to be of concern in my case.

My truck was running perfect then it just went to crap in about 30 seconds when driving down the highway and barely made it home when it promptly died and never started again until I replaced the IDM

Not sure if the rubbed wire killed the IDM but you may check yours to be safe.

It was quite dry that day and it never gave me trouble in rain either.

What is the orange wire anyway????

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1 - 9 of 9 Posts

EXODUS

· #2 · Sep 10, 2011

Thanks for the heads up...I'll look at mine this week-end.:thumbsup:

Peace
Robert

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klhansen

· #3 · Sep 10, 2011

Lee157 said:
What is the orange wire anyway????

The orange wire is the common high voltage feed to the 4 injectors on the passenger side bank.

Glad you got the problem figured out.

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Lee157

Discussion Starter · #4 · Sep 10, 2011

klhansen said:
The orange wire is the common high voltage feed to the 4 injectors on the passenger side bank.

Glad you got the problem figured out.

Passenger side I'm showing 1 and 7 as bad injectors in buzz test could that orange wire have had something to do with that?

.

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klhansen

· #5 · Sep 10, 2011

Sure could. You need to make sure you have those chafed spots taped up well so they won't short.

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Lee157

Discussion Starter · #6 · Sep 10, 2011 (Edited)

klhansen said:
Sure could. You need to make sure you have those chafed spots taped up well so they won't short.

Well then that could explain why they all went bad at the same time.

Cleaned the harness with carb cleaner, then blasted with starting fluid to remove all oil then put a big bugger of silicone over the whole area then put a 6" long piece of 1" dia split loom over the whole thing,,,, it'll play hell gettin at the copper again. Silicone is much better than tape on an exposed wire, just need to get it real clean for a bond.

put loom over that lifting eye and around the harness in that other spot as well.

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ford_doctor

· #7 · Sep 10, 2011

That was a semi-common problem years ago... but I don't see too many 7.3's anymore.

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Lee157

Discussion Starter · #8 · Sep 10, 2011

ford_doctor said:
That was a semi-common problem years ago... but I don't see too many 7.3's anymore.

yes and it's sad for me being a Ford guy because I never buy new vehicles and for me that says I'll be open to a Dodge now since the 6.0 is something I'll never have and I don't know much about the 6.4 other than it lived a short life as for model years and the new ford engine will be out of my budget for some time.

I'm just working with these trucks and makes no sense to me buying a $40,000 truck that I have to pay for while it's getting beat to hell.

I'll buy a $10,000 truck and take a few weeks off work.

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Andrew G

· #9 · Sep 11, 2011

When the same thing happened recently to me, I inspected the wires and found that they were ALL exposed to one level or another on the drivers valve cover. The insulation was simply crumbling off of them. New IDM solved the drivability, and I unpinned and installed heatshrink on all the individual wires. Not sure why the insulation was so bad on the wiring, but at 215,000 I suppose an IDM is due...

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