1. As a rule I always remove any chip or program before trouble shooting, It saves chasing ghost. I recommend you do the same.

2. The Ford Factory Service manual is very specific about how you solder in those pig tails. Do yourself a favor and do not just crimp them but do a proper solder job.

 

See if I can post pics now....

this was a small small and not broken all the way through but when shorter to the other broken and bare wire next to it cause all sorts of intermittent problems and all the OMH and voltage drop testing never turn up a thing.

point being..... be through in your investigation.

 

I looked really closely at the wiring harness and did not see any chafed wires. I ordered the valve cover gasket and harness from riffraff. I took it all apart this afternoon and found an exposed wire under the valve cover. It was on injector 2. I almost jumped for joy. I took out the gasket, installed the new one. Plugged in the 42 pin. Buzz test paassed. Ran it four more times. Passed, passed, passed, passed. I climbed down from the top of the truck and actually jumped for joy.

Since it was fixed in less than an hour I went ahead and installed the fuel rail crossover and high pressure crossover I got from riffraff when I ordered the gasket. I left the connector pigtail for now and did not do the passenger side. I have all the parts though and will get to it when I get a chance.

i drove it about 20 miles. Not a single hiccup.

All total, about 4 hours of work. I can’t believe that I paid two different shops who totally missed this busted wire insulation. I guess I learned two lessons on this one. 1. Don’t use any aftermarket parts on this truck. 2. Fix it myself.

Well, at least now I have a brand new alternator, all new sensors, new idm, New injectors, new injector wiring harnesses and gaskets, new turbo, new intercooler, new air intake, new frx and hpx, new glow plugs, new starter, new chip, new exhaust, new turbo pedestal, and a whole lot of knowledge and experience with my rig. Now watch the motor blow up.

thank you all very much for your input.

 

No way that bad boy will blow up. You gave it the needed care and feeding. I know that jump for joy feeling. Pretty satisfying to have done it yourself.

 

Yup, it is a glorious feeling when you find that wire yourself, The local dealer and the best independent shop around both missed mine and both replaced #3 injector, that was the last time i ever paid to have my 7.3 worked on.

 

I wish I knew how that insulation got cut. I was very careful when I installed the gasket because I had read threads on this forum about not pinching the wires. I wonder if that is evidence of poor quality manufacturing or if i did something during the install.

 

I recently replaced both the gaskets and wiring harnesses in my truck with International parts from RiffRaff. The driver side harness on my truck was a Dorman part, the passenger looked original to the truck.

Once I had the Dorman harness out, and compared it side by side to the International part, the difference was very clear. The International part was far superior in several ways and I was glad I made the call to remove the Dorman part, despite the fact that it seemed to be operating properly. I only replaced them as preventive maintenance as I was in there replacing glow plugs anyway.

Nice find and most of us know that jumping for joy feeling.