Broke wires when installing headers (Help!!) - Off-Road Forums & Discussion Groups
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post #1 of (permalink) Old 10-01-2006, 10:12 PM Thread Starter
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Broke wires when installing headers (Help!!)

Hey guys,

Well when I was installing my header I was pulling the intake manifold off the head and snap!!! I snaped some wires in half... and thats not the worst part. The worst part is that I cannot figure out where the wires go!!!! So If you guys could help me and let me know where they need to be reconnected that would be great. The wires come from behind the head somewhere. Here is a picture of what it looks like.

http://brannon132.myphotoalbum.com/v...01&id=IMG_2801

Thanks a bunch, Brannon
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post #2 of (permalink) Old 10-01-2006, 10:27 PM
 
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Re: Broke wires when installing headers (Help!!)

A few questions come to mind. Is it safe to assume this is a 99 TJ and a 4.0L engine?

Does it run?

Can you check for trouble codes?

Does everything work, or, what doesn't work?
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post #3 of (permalink) Old 10-02-2006, 12:20 AM Thread Starter
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Re: Broke wires when installing headers (Help!!)

Im pretty sure the wires run to this connector

http://brannon132.myphotoalbum.com/v...01&id=IMG_2806
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post #4 of (permalink) Old 10-02-2006, 08:45 AM
 
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Re: Broke wires when installing headers (Help!!)

[ QUOTE ]
Im pretty sure the wires run to this connector

http://brannon132.myphotoalbum.com/v...01&id=IMG_2806

[/ QUOTE ]

Bad link with no answers.

[ QUOTE ]
The file you're looking for doesn't exsist or has been moved. Or, maybe the other files just didn't like that one and they all ganged up on it and harassed it until it left. That would be sad. Anyway, it's not here.

Actually, we couldn't find the page you requested. Please check the URL.

[/ QUOTE ]
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post #5 of (permalink) Old 10-02-2006, 09:54 AM
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Re: Broke wires when installing headers (Help!!)

[ QUOTE ]
Im pretty sure the wires run to this connector



[/ QUOTE ]

The sheath doesn't look crushed, so what clipped the line? Was the line pulled out of a connector (look for stretched insulation) or clipped (look for clipping on the wires/insulation)?

Do the harness wire colors match the connector wire colors?

Is there a number on the connector in question?

Can you take it out and get a better picture?

Where does the mating side of that connector run?

Also, from your pictures the wiring harness is long. It would not make sense for it to be folded in half and returned to a connector near the splice. Detroit doesn't waste wire like that.

Is there a natural bend to the harness, or have you stretched it out? If you haven't stretched it out then take a look at it's natural bends and see if you can find something within it's reach.

Last edited by LEVE; 03-24-2009 at 07:43 PM.
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post #6 of (permalink) Old 10-02-2006, 10:21 AM
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Re: Broke wires when installing headers (Help!!)

Hard to tell.....but because of the protective cover on the wire, it most likely runs pretty close to the exhaust manifold. If you have a connector missing a wire, then there is a good chance that is the connector.

A couple of observations....

It would appear that you tried to install the header with the intake still on....you would have been better off removing all of that stuff to do it...

Why the header?...assuming it's a real header and not a stock exhaust manifold....I personally think you are going to regret this after a very short period of time.
post #7 of (permalink) Old 10-02-2006, 03:38 PM Thread Starter
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Re: Broke wires when installing headers (Help!!)

Well it took me a couple hours and I couldn't find out where it went. So I cheated and went to a dealership and looked under the hood of another wrangler. The wire goes from the back of the intake manifold to the top of the tranny. It looks like some kind of sensor. I dunno what this does but im off to rind a replacement. The wires snapped from so close to the sensor that I cant reconnect them. Well thanks for the help.
Brannon
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post #8 of (permalink) Old 10-02-2006, 03:43 PM
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Re: Broke wires when installing headers (Help!!)

It could be the speed transducer. Go back to the dealer and when they find the part on the computer ask for a print out and the Part Number. With that I should be able to tell you what it is.

You said it goes to the transmission. Is it an auto, or manual, and where on the transmission do you find the device. I suspect it's a CPS sensor, or the like, but that would keep it from running.


Last edited by LEVE; 03-24-2009 at 07:43 PM.
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post #9 of (permalink) Old 10-02-2006, 04:03 PM Thread Starter
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Re: Broke wires when installing headers (Help!!)

Thats it!!! Its a 6 cylinder engine. What is that called? I think that I am going to head over to walt and verns and see if they would have it first. Thanks so much Leve.

Brannon
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post #10 of (permalink) Old 10-02-2006, 04:24 PM
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Re: Broke wires when installing headers (Help!!)

It's called the CrankshaftPositionSensor (CPS). It's also known as the TopDeadCenter sensor (TDC). Send me your Email and I'll send you a FSM section on the Ignition that will explain the sensor and how it works.



Last edited by LEVE; 03-24-2009 at 07:43 PM.
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