[urq] intermittent ignition cutout and other adventures

[Ed Kellock]

A full day of urq wrenching...

I received the loaner ignition module (thanks Dennis!) and set out to install it today.

I learned about thermal conductive grease.

I found a pin that was damaged in the connector to the ignition module.  Replaced that.

I removed the jumper wire from the ignition module to the ecu (inherited from previous
owner).
I removed the jumper wire from the ignition switch to the fuse box to the coil (inherited
from previous owner).

I pulled the fuse box panel up and took another look at the fried wire (inherited from
previous owner) that I saw in there a couple years ago.

Got very familiar with the wiring diagram and found that it is a ground wire from G31 to
ground point 13 (welded, wiring harness instrument cluster) and it serves pin 50 of the
fuel pump relay, pin 18 of the radiator cooling fan relay (2nd stage), pin 27 of the load
reduction relay, and pins 44 & 23 (not used) of the washer/wiper intermittent relay.  It
has no insulation for as far as the eye can see, about an inch and a half, before it
disappears into a wrapped bundle.  Scratched head and reinstalled fuse box panel.

I disconnected the radio power wires from fuse 5 and fuse 16 (I think).  The wires for
power and power trigger were run to the fuse box (through a hole neatly bored into the
side) and the bare wire ends were inserted into the fuse slots with the fuse jammed in on
top of it.  Neat.  So, no radio for a while.

Went for a test drive and still experienced ignition cutout.

Decided to pull radio wires through center console to passenger side until I can pull
radio (Pioneer something or other) to do proper install.  Found larger 8-pin connector
loose in near heater box on top of trans tunnel.  Found big silver box which would accept
8-pin connector with no connector.  Guess that's why I have no cruise control.  Could not
find receptacle for smaller connector which piggybacks off 8-pin plug.  Will purse further
later.

Decided to go after non-functional diff locks.  Found main vacuum feed line pulled loose
from switch.  Found second diff lock switch plumbed into system, mounted to side of
console panel.  Disconnected it and used it (obvioulsy newer unit) to restore original
connections.  Figured out proper connections from erroneous Bentley which shows "later"
version still with push/pull switch.  Connected everything back up and went for a drive to
verify diff lock operation.  Appears to be good.

Also experienced no ignition cutout.  I'm guessing it's a coincidence.

I believe the second diff lock switch was plumbed so the rear diff could be locked
independently of the center.

Readjusted mixture according to best steady idle.  Idle speed too high.  Turned idle speed
screw all the way in to stop.  Idle still just a tad over 1k.  Sprayed brake parts cleaner
at injectors.  Idle speed momentarily lowered to something closer to normal.  I guess
those injector inserts are leaking again.

Ed