I found my issue that has been plaguing me since Relic Run last year....long story short, at Relic last year, my truck started running like crap, and had to limp home 400 miles (thanks again
@Svensk120 for the tail in case I completely broke down!) Found what I thought was the issue which was a faulty (or so I thought) EGR bypass resistor that I put in about 4 months prior to that trip. after a month of diagnostics, I removed that and ran fine until Wolf Den on New Years Day. On the ride home and on the first paved hill out, when the trans downshifted, my exhaust rattled and banged quite a bit.
@TRDdrew (riding shotgun) and my son following, figured that I just bent the muffler/tail a bit and it was hitting my bumper (a few trucks including
@Jakes40 's Tundra) took a beating on one obstacle that was hard on the tail ends for just about everyone. After getting home, I did see a slightly bent rear pipe/resonator that was tapping on my mudflap tab on the bumper...bent that out of the way, all good.
Fast forward a month without driving the truck at all due to the snow/salt all over the roads...got in it for a daily run...kicked down a bit and it still felt terribly boggy and underpowered with the extra throttle (easy driving seemed normal). On a whim and following the EGR delete thread on the 80 forum, I decided to re-try the EGR bypass resistor. After installing it, the truck ran like crap, but unfortunately unlike last spring after going right back to stock, it still ran like crap!
With this new must-solve issue, I decided that it was time for a manifold pull and full clean up, injector cleaning, fuel filter (under the intake), associated vacuum lines, etc. The 93-94 80 series is known for melting the harness near the EGR pipe, so planning to delete that too and carefully inspect the harness in that area (the PO did put some insulating wrap in the problem area). I got a spare harness and noted that the #6 injector and EGR temp sensor feed wires are tied to a mini branch back in that area, so it would be a place to inspect carefully.
Before completely removing the intake, I inspected that area and started tugging on wires...turns out my #6 injector harness plug was completely disconnected! Throttle body off and upper intake loose (as far as I got before family dinner last night) shows the harness plug broken and no locking tab anymore...also lots of corrosion in the harness plug and on the actual injector wiring pins, so this has been a sleeping gremlin just waiting to bite me!
I'll still pull the entire intake off, replace all of the injector pigtails, clean (or replace) the injectors, EGR full delete, and all of the other goodies already mentioned for the maintenance while this is apart...fun times ahead and hopefully a happy and strong running 80 once complete!
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