Contour Enthusiasts Group Archives Forums General Troubleshooting Intake System Rebuild - New Problems

I completed the intake overhaul on my '95 duratec as described in the HOWTO (thanks, Lance), and also replaced the main wiring harness (injectors, et al). The old harness was a disaster.

Now I seem to have the same old problems and some new ones, too. First of all, everything was very dirty but cleaned up well. I used all new gaskets, etc as prescribed. I did not replace the EGR valve (or clean it - only the intake components). I still have codes and the CEL, and now when I hook up the MAF, the idle zooms up to around 2000-25000 RPM and stays there.

How do you clear the codes??? I can leave the battery disconnected for 24 hours, and without ever starting the car I still have the same codes (113, 519, 551) when I perform the "key on, engine not running" test. The 551 code (IMRC) has been around for the last 10K miles. The butterflies were a mess, but are clean now.

In the end, I am in worse shape than when I began. Any further trouble-shooting ideas? I dread the thought of taking this thing to the dealer.

Did you replace the fuel injection harness or the computer harness that the fuel injection harness plugs into (the two 12-prong plugs and the 4-prong plug)? The computer harness also plugs into the computer behind the power steering reservior.

Because everything it's complaining about is on the computer harness, and the computer harness is one of 4 harnesses that are replaced during the recall (the injection harness is the other, and I forget what the other 2 are).

Brian

Also thought I'd mention that Ford sells the 4-harness repair kit for roughly twice what the fuel injector harness costs by itself...

See here for more info:

http://www.geocities.com/flceg/

Brian

The only harness I replaced was the fuel injector harness. At least the car was drivable before - now it is not.

HOW DO YOU RESET THE CODES??? DISCONNECTING THE BATTERY FOR 24 HOURS DOESN'T SEEM TO DO IT.

HELP!!!!!!!!

That's because the codes you are getting are probably NOT memory codes.

They are hard fault codes. The hard fault codes come before the memory codes with a single "separator" blink between them. Hard fault codes indicate problems that the computer sees during the engine-off self test.

I'll walk through these codes:

113 (O,M) IAT sensor is/was high or open - IAT

This most likely means that the IAT is either not connected or the wiring to it is damaged. This code CAN be a memory code.

519 (O) PSP switch/circuit open - PSP

Again, a possible wiring problem or disconnected connector. This CANNOT be a memory code, it is only produced when the engine off self-test is running.

551 Problem in Intake Manifold Runner Control (IMRC) solenoid/circuit - Solenoids

Also a possible wiring problem or disconnected connector.

You may want to check the wiring, but I'd guess you'll find that the main engine harness isn't in any better shape than the fuel injection harness. Mine has bare wires going to the IMRC solenoid, and that's just the part I can see!

Brian

Brian

Brian,

Thanks for the reply. I guess the concensus is that I should replace the remainder of the wiring before doing anything else...what a bummer.

This car, which I have owned for 3 1/2 years now, has really been enjoyable, with the exception of the poor engineering that Ford put into it. It is pitiful, really - I have owned dozens of cars over the the 28 years that I have been driving, and I have NEVER had a car with so many obvious design and engineering flaws. And this wiring harness ordeal is really the last straw. Is it a surprise that this is my first Ford product? It is certainly my last.

I will keep you all posted on my progress - I will call Atascadero Ford in the morning to order the other wiring harness(es). They have been very helpful.

Mike

I don't know what kind of MORON was responsible for using the wrong kind of insulation on the wires.

Especially since high-tech test equipment like a soldering iron or a lighter can confirm whether the insulation is the right type.

It *MAY* be cheaper to order the harness kit...see the link I gave above...especially if you want a long-term repair since there are two additional harnesses that should be replaced in addition to the fuel injection and engine harness. I got the harness kit for $650+shipping from Bill Jenkins, this is for my '95 with V6/ABS/5-speed.

Brian

I guarantee you he (or she) was an accountant, ignoring the advice of a roomful of material engineers and giving his boss what he wanted (lower cost). I always hated dealing with Ford's accountants and/or purchasing agents for that reason. They seem to have the incredible ability of completely ignoring an expert's direction on what is best (or what is minimum required).

Okay, I need some additional information here. Atascadero (Ford Parts Online) could not identify the part numbers for the other three harnesses. I have already purchased and installed the injector harness (paid $390), but now I need the other three. Is Bill Jenkins back in business yet?

Thanks in advance for the help!

Mike

Bill Jenkins can be reached at this number:

800-876-3280

That's Signature L/M.

The part number for the harness kit is in the 99m03.zip file at the above link...

Brian