help burnt wiring harness
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Posting Guru
Joined: Aug 2007
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From: Cato Arkansas
help burnt wiring harness
i am in the process of installing new glow plugs and stage II's 
and noticed that on the driver side the back wiring harness by the turbo that plugs into the valve cover the outside pin is burnt. Do i have to replace my whole wiring harness or can i just buy that one connector? and what does the outside pin do i can't remember
and noticed that on the driver side the back wiring harness by the turbo that plugs into the valve cover the outside pin is burnt. Do i have to replace my whole wiring harness or can i just buy that one connector? and what does the outside pin do i can't remember
Hotshot
Joined: Aug 2006
Posts: 10,764
Likes: 39
Some parts for repair
Valve Cover Harness Repair Kits (contains 4 hard shells w/seals, w/o terminals)
(Ford) F7TZ-14489-BA (94-96)
(Ford) F7TZ-14489-AA (97)
(International) 1830829C91 removal tool and Shells w/o pins
(International) 1661875C1 Pins
(International) 2501055C1 Pins with 6" wire
Valve Cover Pigtails with plug and wires, OBS
(Performance Specialties) 99288
Valve cover harness replacement terminals:
Industry P/N 103935; Winzer Distributing (1-800-527-4126) selection number D52
Valve Cover Harness "Wedge" repair (not sure of years it fits or what it looks like)
(Ford) 2c3z-14a163-ab
Valve Cover Gasket (94-97)
(Ford) F4TZ-6584-A
(International) 1818350C2
Valve Cover Harness, under valve cover
(Ford) F4TZ-9D930-K (94-97)
(International) 1815923C92 (94-97)<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com
fficeffice" /><o
></o>
<o> </o>
& also …here…. Powerstrokeshop.com
Valve Cover Harness Repair Kits (contains 4 hard shells w/seals, w/o terminals)
(Ford) F7TZ-14489-BA (94-96)
(Ford) F7TZ-14489-AA (97)
(International) 1830829C91 removal tool and Shells w/o pins
(International) 1661875C1 Pins
(International) 2501055C1 Pins with 6" wire
Valve Cover Pigtails with plug and wires, OBS
(Performance Specialties) 99288
Valve cover harness replacement terminals:
Industry P/N 103935; Winzer Distributing (1-800-527-4126) selection number D52
Valve Cover Harness "Wedge" repair (not sure of years it fits or what it looks like)
(Ford) 2c3z-14a163-ab
Valve Cover Gasket (94-97)
(Ford) F4TZ-6584-A
(International) 1818350C2
Valve Cover Harness, under valve cover
(Ford) F4TZ-9D930-K (94-97)
(International) 1815923C92 (94-97)<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com
fficeffice" /><o></o><o
> </o>& also …here…. Powerstrokeshop.com
New User
Joined: Nov 2008
Posts: 4
Likes: 0
i am in the process of installing new glow plugs and stage II's and noticed that on the driver side the back wiring harness by the turbo that plugs into the valve cover the outside pin is burnt. Do i have to replace my whole wiring harness or can i just buy that one connector? and what does the outside pin do i can't remember
and noticed that on the driver side the back wiring harness by the turbo that plugs into the valve cover the outside pin is burnt. Do i have to replace my whole wiring harness or can i just buy that one connector? and what does the outside pin do i can't remember
Here is where I bought the valve cover kit: http://cgi.ebay.com/ebaymotors/ws/eB...3AIT&viewitem=
Last edited by 9573L; Nov 28, 2008 at 05:34 AM. Reason: Adding info
Hotshot
Joined: Aug 2006
Posts: 10,764
Likes: 39
From Racer_X :
Excess resistance in the circuit is what causes it to burn the harness. Wiring is to small to handle the heat when the plug doesn't use the amps up to heat the tip. Heres a simple explanation:
Ford/Nav VC gasket/harness was redesigned with better conductors several years ago. Here's a basic way to explain it without math at all:
If the glow plug (load) were to short, the burn or weld will happen at the point the short occurs. If you use a welder it welds at the electrode (load). It won't burn up your weld cables.
So why does the harness connector melt? Excessive Resistance causes heat. A GP has little resistance or ohms. It's nearly full power that warms the tip using up power to make heat. What little power isn't used returns thru ground to battery completing the circuit. Excess resistance or poor conduction from green stuff or corrosion prevents full power from flowing to the load (glow plug). The wiring gets hot and melts because you still have a complete circuit back to battery ground, but no load to use the power up and keep the wiring cool as power flows thru it.
Now think of the welder again. What happens if you forget to put a ground clamp on the metal to be welded and touch the electrode (load) to the metal? Nothing. The circuit is not complete, so no power flows at all. No weld or short.
Best way to prevent the burned wiring is a good conductor to your GP's. I pack Di grease in all underhood connectors. The best way to keep the connection moisture free and clean is silicone dielectric.
If your harness burn't from the GP connector back, then you may have a shorted plug. Ohm it, compared to the others. If it ohms out higher than the rest it's also BAD. The extra resistance is inside the plug, not allowing full power to the tip.
-
Excess resistance in the circuit is what causes it to burn the harness. Wiring is to small to handle the heat when the plug doesn't use the amps up to heat the tip. Heres a simple explanation:
Ford/Nav VC gasket/harness was redesigned with better conductors several years ago. Here's a basic way to explain it without math at all:
If the glow plug (load) were to short, the burn or weld will happen at the point the short occurs. If you use a welder it welds at the electrode (load). It won't burn up your weld cables.
So why does the harness connector melt? Excessive Resistance causes heat. A GP has little resistance or ohms. It's nearly full power that warms the tip using up power to make heat. What little power isn't used returns thru ground to battery completing the circuit. Excess resistance or poor conduction from green stuff or corrosion prevents full power from flowing to the load (glow plug). The wiring gets hot and melts because you still have a complete circuit back to battery ground, but no load to use the power up and keep the wiring cool as power flows thru it.
Now think of the welder again. What happens if you forget to put a ground clamp on the metal to be welded and touch the electrode (load) to the metal? Nothing. The circuit is not complete, so no power flows at all. No weld or short.
Best way to prevent the burned wiring is a good conductor to your GP's. I pack Di grease in all underhood connectors. The best way to keep the connection moisture free and clean is silicone dielectric.
If your harness burn't from the GP connector back, then you may have a shorted plug. Ohm it, compared to the others. If it ohms out higher than the rest it's also BAD. The extra resistance is inside the plug, not allowing full power to the tip.
-
Posting Guru
Joined: Nov 2001
Posts: 1,743
Likes: 2
From: Ft Scott
Yes, and they eventually figured it out, starting with the 99's instead of two five wire connections on the VC gasket they use a single nine wire connection with bigger wires.
Postmaster
Joined: Sep 2007
Posts: 4,195
Likes: 6
From: Medford Oregon
x2 .. weak link is the actual plug connector(s). Anytime you go through a connection there is some heat generated due to contact resistance on the plug(s) pins. Best thing to do once problem is corrected never unplug the connection unless you absolutely have to for troubleshooting.
Thread Starter
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Posting Guru
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From: Cato Arkansas
thanks for the help guys got a new problem now some how when i was orangizing all my bolts i pulled out of the engine i noticed a injector old down bolt missing i spend 2 hours today looking for it and like 2 hours yesterday can't find it any where i just hope it hasn't found its way into the engine which i don't think it did
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