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After sorting through endless wiring diagrams and my burned up heap of wires, I have concluded that there are FOUR harness groups under the hood. I don't know the technical names for them, but here's what I'm calling them:
1. Engine harness (injectors, COPs, various sensors)
2. Main power harness (lights, cruise, heat, wipers, ABS, power distribution box)
3. Charging system / A-C harness
4. Starting system harness
The engine harness, charging/AC harness and starting harness all seem to be pretty universal for V10 Excursions. The main power harness is the one that seems to have a bunch of variations, depending on how the vehicle is optioned.
I've decided that in order for me to find a harness I can use, it would be a good idea to know what I have. So I laid out the scorched harness and began labelling, noting and tracing. I'm breaking it down in two parts- right front and left front.
Yesterday, I started with the easy side- the right front (the unburned side). The left front is going to take some time due to the damage and complexity. Here's what I have so far...
Last edited by Psyclopse; Apr 9, 2015 at 11:42 PM.
Reason: Corrected information.
Today, I focused my attention on the "charging system / A-C system" harness. This is the harness that plugs into #8 on the picture in my last post.
Since this harness pretty much resides on the right side of the engine compartment, I didn't expect there to be much (if any) damage to it. Nevertheless, I completely disassembled the wiring out of the harness, cleaned everything up, tested each wire and plug, then reassembled the harness.
For your viewing pleasure, I took a picture of the newly cleaned and rebuilt "charging/A-C harness." I also labeled the connectors and created a wiring diagram (I figured if one person ever benefits from it, it was worth it)...
Sorry the labeling is kinda hard to read- it was hard choosing a color that shows up well on OSB board...
It's funny how bad something looks when the melted plastic and rubber, and the smoke damage is all still intact! Most of the smoke damage is washing off pretty easily with Dawn dish soap. The aluminum is a different story- seems this method just isn't getting the intake manifold cleaned up at all- when it dries, it looks just like when I started! I'm not really wanting to pull the intake, since there is no damage there, but I really don't want it to look like I pulled it out of a forest fire...
I did pull the elbow on top of the intake and the throttle body though- not only to clean them up, but it makes dealing with the harnesses A LOT easier. I'm probably going to pull the alternator sometime this weekend and have the 'zone test it. I imagine it's just fine, though it looks like the intake...
The only concern I have as far as fire damage is the LF fender support (is that what it's called?). Being hollow, I want to get something up inside of it so it doesn't rust out over time.
I would pull the aluminum parts and find someone that does walnut blasting. A powdercoater can do this usually. We used to walnut blast aluminum Corvair engines and it cleans them right up without letting sand contaminate the parts.
I would pull the aluminum parts and find someone that does walnut blasting. A powdercoater can do this usually. We used to walnut blast aluminum Corvair engines and it cleans them right up without letting sand contaminate the parts.
I'll have to look into that. I already have a bunch of brackets and stuff from the left side of the engine compartment that needs sand blasted. I'll just get a quote on walnut blasting the aluminum stuff too. But man, I really didn't want to pull that intake! Haha.
To be honest, it'll come down to cost. I have a truck load of little stuff to source and buy and not much money each month to do it.
I have 5 plugs under the brake booster that join to wiring that goes under the truck. There are three 16-pin plugs, one 12-pin plug and one 8-pin plug. I can't tell what color they are, because they are charred pretty good.
I "think" the connector names are C103, C1044, C1045, C1046 and C1047. Can anyone verify this and correct me if I have it wrong?
Also, I've searched Google for hours and can't come up with a pin-out for these connectors on a 2000. Even if the pin-out only shows wire colors, I can get the rest...
I have the Ford software with diagrams but wont be able to look them up until tomorrow afternoon. I will post up the pictures when I can sneak away from work.
The software does not show a diagram for c1047. It is the correct name though. If you need the diagrams for it I can get the actual wire diagrams with color codes but not the connector diagram.
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