Here it is, by popular demand.
If we get it, we get it. If not, well...I don't know.
But I'd rather get it running again since besides the engine, it was a good solid truck.
It's been an Arizona truck all it's life, and there is hardly a dent, nor a speck of rust on it.
Everything works, including the AC.

This is an 86 XLT 4x4 automatic 302 Electronic fuel injected.

There may be some stupidity involved here, and if you need to, call me names, I can take it.

Here's the story:

I bought this 5 years ago, and all I ever did to it was drive it, replace tires, and a battery, and change the oil.
Nope, wait, there were some other things, but nothing major.
No earthly idea how many miles are on it, but you can bet it's over 200K.

For starters, I've had this problem since day one.
On very hot days, and or pulling 10% grades to my home the truck would just quit.
You could crank all you wanted, but it wasn't going to start until it sat for 15 minutes or so, then it would run like nothing happened.
The temp needle never rose above 3/4.

Now I'm not a mechanic, but I'm fairly ok at diagnosis, and simple repair, but I'm more familiar with old school points, plugs and carbs.

I asked around about this problem, but my local folks weren't much help.
At one point there was a fuel problem, so we pulled the bed off and replaced both in tank pumps.
The problem persisted.
Another suggestion was to replace the fuel pump relay. Someone suggested maybe it was getting over heated.
That didn't solve it.
The engine never boiled over during any of this, and I'm pretty certain that I checked the coolant level, but I wouldn't bet my life on it.

So anyways, a few months ago I was coming home with a heavy load. (forklift battery)

I turned onto my road and made it just past the point where it normally quits.
The climb is about 6 miles with grades at close to 10% along the way, after which I turn onto my road, and slow down quite a bit.
( I would venture to guess that this is when all the heat accumulates)
Right as I slowed down, I smelled burning organic material like leaves.
At first I thought maybe I had knocked the cherry off my cigarette, but I continued.
Then the truck died, as about usual, but now I smelled not only organics, but electrical.

I saw some smoke come out from under the hood.
I pulled the latch, flew out of the truck, and opened the hood.

Right under what I guess you'd call the air intake/injector manifold (Top rear of engine, big silver thing) there was a small fire underneath.
I'm fairly certain what caught fire was the makings of a mouse or pack rats nest, then maybe some wires.
Fortunately I had a canteen with some water.
I managed to splash enough under there to get it out before the truck went nuclear and burned to the ground with thousands of dollars worth of battery in the bed.

I didn't bother trying to restart it, and just dragged it home with my Jeep.

I'm not at all familiar with the intake injector system.
I watched a few yootooobs on it, and decided I wanted nothing to do with it.

I'm not a wealthy man, so I put an ad on CL, just to see if someone wanted to tackle it.
I got a call From "Billy" who said he had a shop a few towns over, and was certain he could fix it.

After about a week, he said it needed two injectors, I ok'd the job, and told him to do it.
Two weeks went by before he said he had them installed, but couldn't get the truck to start because the battery was dead.
Come to find later, my new battery was indeed dead because he had hooked up the secondary battery which had been out of line since day one.
Then he said I needed a starter. (I've never ever had a problem with the starter.

Being at my wits end I told him, fine, put one in.
Turns out it didn't need a starter, so he quote/unquote put the old one back. again.

Another week later he calls and tells me the truck is ready.
I drive almost 70 miles, pay his wife 300 some odd dollars, and go to start my truck.
It starts, and runs like crap.
Missing and black smoke, like it's running too rich and missing.

I ask Mr Billy, WTF is this????

He replies, Well, I replaced the injectors!!!
I said, well it's obviously not running right, is it???

Two weeks later he flat out gives up.

Enter the next guy.
He says, this should be easy.
I have the truck towed to him.
I'm now into this repair for over $600 with tows and Billy's fail.

The new guy is stumped.
From what I recall, he replaced some plugs, the cap, the rotor, the wires, and what else I don't know.
I somehow don't think he replaced the ECM or coil, but I'm not sure. And I almost don't want to bug him.

He gave up as well, and the truck still runs like crap.
He did say he did a compression test and it was good.
I just got the truck back yesterday, and have been too busy dealing with my other truck previously posted in the 7.3 powerstroke forum, to look at it.
I paid him $200 for parts, and he only charged me $200 for his time, since he too couldn't get it running.
So now, I'm nowhere, and $1000 into this.

Now, I have to ask myself, does the top of the engine ever really get that hot to start debris on fire?
Why did the rats nest burst into flame?

Maybe the heat destroyed or warped the intake? I don't know.
Maybe Billy never really took it apart and replaced anything. I can't really tell.

So, this is where I'm at today.
I like this truck.
I'll never get any money out of it selling it as is.

If I had the money, I'd take it somewhere and have a new engine put in, but I don't have the thousands for that.
I'd like to get it running again, but I'm about to start a house addition on my home, and I can't devote my entire attention to this truck.
Nor can I spend much more money.

So if you guys want to help tackle this, I'm game, but not rich.

As a side note, when I bought the truck, the guy threw in two fresh heads because he said he planned on rebuilding someday, so there's that.
But at this point, I don't know what to do, or where to even start.

Ok, have at it!

 

I think think the old problem you had will tie into this at some point. But for now lets start with what happened during the fire. Care to take some "forensic" photographs. Show us how it is as it sits, then more photos as you uncover things. Let us get an eye for the damage done. We respond well to pictures We are mostly here to help, so I'm pretty confident we can help you diagnose it and get it back on the road, as well as run you all over the place checking things. But if you are slow and patient and like to sit and ponder, chances are we can help without much or any unnecessary expense.

The fact that it fires is a good sign, sounds like your shade-tree mechanics got it most of the way there. I don't have much experience, but I'm willing to donate what little I do know, plus my time doing research to help figure this out. Sounds like a lot of fun.

 

I'll take a few pics later this morning when the sun is up.
There won't really be much to see, I don't think.

There was no visible damage one could see after the fire, it wasn't very big, and was contained under the intake.
I forgot to mention that right before I had it towed the first time, I threw caution to the wind and cranked it over, and it did start, running like crap.
So to put things in perspective, it currently runs no better than it did when it left.
I'm going to need to disconnect the bad battery, and see if I can get what was once the good one to take a charge.
I haven't tried starting it since it got back home.
I'll be back later.

 

Ok.
Here's a video I shot today. Sorry for the amateurish shoot.
I'm not too good with the iphone.
It's definitely not running right, and there's little improvement after two people worked on it.

 

How well equipped are you? Do you have a multimeter, spark tester, fuel pressure tester? And have you ever pulled diagnostic codes on an OBD1 system?

I'd start with the trouble codes just to see what they say. I'd also test the fuel injectors with a multimeter. Verify plug wire routing and firing order, inspect the plugs, verify spark gap and test for spark. Also worth doing a fuel pressure check at the fuel rail. Should test the pressure regulator as well. A vacuum leak check wouldn't hurt either, using carb and choke or an unlit handheld propane torch.

I'm still curious about the wiring near the fire and what it went too. As well as your shade tree mechanics. Did you explain everything the past problem to them as well as the rats nest? What was their reaction and what did they say about it? Did either of them remove the upper intake plenum and did they put a new gasket on?

 

fuel pressure test kit free at most box auto stores local on their tool deposit program. Use it, don't break it, carry it back, no charge! Just got one from Oreilly couple weeks ago.

 

Plenum? Is that what the big gray intake manifold gizmo is called?
If in fact it is the thing (Stamped Ford) displayed in the video thumbnail, that's was where the fire was under, and looking at the bolts it appears they have been untouched.
I specifically told both of them that that would have to come off. It appears they didn't listen.

I don't know how to get codes on this truck. I have a multimeter, but no spark tester, nor fuel pressure gauge.
Supposedly guy #1 replaced 2 injectors.
As I said previously, I am not familiar at all with these fuel injected engines, hence my reluctance to tear it apart and send it to someone else.

 

Is this a disconnected spark plug wire? Beginning at around 3:26 into it:




If it were me, I would remove the plenum to investigate & repair damage caused by the fire. At least ensure there is no shorted wiring.

Then pull the computer codes, see what the computer says is going on.

 

Here is a good introduction to pulling codes:

https://therangerstation.com/tech_library/OBD_I.shtml

 

He's a quick video on testing injectors with a multimeter.

The basics process of pulling codes, just to give you a visual. The rangerstation rundown Chris posted is the way to go.
And since I'm posting links to youtube, @ctubutis I haven't gotten around to photo me doing this, but here's a video lol

 

OK I see now, thanks

 

Thanks guys. The disconnected plug wire was one just laying there from when the last guy replaced the plug wires.
I'm gonna pull the plenium like should have been done in the first place, then I'll watch the videos on codes and injector testing when needed.

 

I believe there is going to be a bolt at the back that may give you some trouble. And one in the middle that everyone says can be a real booger.

 

I've got the plenum loose. It twists a bit.
Hmm,, does it pull straight up?
I need to go find a pic.

 

Should come up, does it lift at all or does it just twist?