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Subject:Re: Broken down travelers need help ASAP
From:David Beierl
Date:Sat, 17 Aug 2013 00:34:35 -0400

At 02:19 PM 8/16/2013, OlRivrRat wrote:
>        Could it be a "D15" issue ~ or Malfunctioning CurrentSupplyRelay in
>the BlackBox above the Coil
>
>
>ORR ~ DeanB

There were a bunch of things it wasn't, but changing the ECU fixed
it.  Unfortunately the bad ECU worked fine in my van, and still
worked fine when we put it back where it came from.

It was a disintegrated ground connection to the ECU.  A PO had
extended the ECU ground by about seven inches so it could be cabled
along with the rest of the harness, using two insulation-displacing
connectors of the type invented by 3M (but not actual 3M ones).  One
of them was running warm and the other had completely melted out the
plastic around the metal insert and the connection had failed.

An iatrogenic** problem was caused by exercising the connection to
the Hall sender on the distributor -- the last six inches of the
wires to the connector had become brittle and broke into many small
segments, damaging the + and - wires leading into the connector; and
we ended up having to heat and strip the brittle insulation with a
torch and build a scaffold to support the damaged wires out to where
good wire could be spliced in.  Bill's got a couple photos.  It's a
work of art, for some value of "art".

They're running and sounding good.

**That's a fancy name for going into a hospital well and coming out
sick, so to speak.

Yours,
David