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ISX

Engine Rewiring

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ISX

I decided to rewire the engine compartment a few weeks ago. I cut every wire in there and took every piece of black tape and ribbed sheathing off and have been left with nothing but wires. My plan is to put the PCM/Fuse Box/Grid Heater Relay on the hood, right on the back drivers side corner. I don't think there will be any issue with slamming the hood and everything getting shock absorption. I have some plans to absorb it a little anyways, though I don't think anything will happen. The initial plan was just to take the ribbed sheathing crap off in lieu of braided nylon sheathing, like what the cruise control has on it going to the throttle. I was going to put it on every single wire. After looking at it some more, I decided to redo everything, every part of routing it. By putting the pcm on the hood, I can get rid of the entire loom that runs along the top of the firewall. I starred at it some more and realized I can get rid of the entire loom that runs along the top of the engine next to the valve covers. There will be hardly any wires on it now and they will be hidden. I am going to use the fuse box for now, but I have plans on getting rid of that big piece of crap as well. This thing has taken me a long time because of how many wires there are and how to run them and where to run them and.... but I finally got one ran to the passenger side headlight lol. I have been working a lot so I don't have much time to work on this thing but I am going to aim for one connection a night now, be done by 2012 :lol:

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Mopar1973Man

Nice job so far for head lights... :smart: I got to admit he's thinking way outside the box... As a matter of fact I think box is a few miles away...:stuned: But I got to agree with him why be plain stock time to be different! :thumb1:

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ISX

The thing about this is that there is no "it looks better than I thought it would" to go along with it because I had absolutely no idea how it would look. Compared to the stock headlight wiring that is zip tied to the bottom of the radiator, I would say it is 100x better. I was going to run it through the crossmember that goes over the top of the radiator, but the goal is to make it easier to work on. By easier I mean easier to work on any part of it, not just some things. So the crossmember idea went out the window since taking the engine or intercooler or stuff like that out, would require removing the crossmember and I would have to completely dewire the headlights/turn signals. By running it down through that square tube that runs underneath the radiator instead, my problems are solved.

I think this would be a lot easier if I had a wire labeler so I could just reconnect them. Right now I have to trace things back, but it's not too hard since everything is a different color.

Another reason I am doing this is because stock wiring is junk. The splices and dices they got going on is insane. I have no doubts anymore as to why you always hear about grounding problems.

I will keep you guys updated.

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ISX

I finally got a weekend off so I got some things done. Well not too much, fell asleep part of the day :doh:I got the passenger side headlight/turn signal/airbag all pulled in so that is taken care of. The biggest thing I wanted to get done TODAY was putting the stuff on the hood. It actually was a lot easier than I thought it was going to be. I thought up a design to mount it and it is so solid that I actually only mounted it with 2 bolts rather than the 4 I was planning on doing. I could pull as hard as I could on just one bolt, so I made another one diagonal to that one to hold the plate in position and it is solid as a rock. I did some guesswork on where everything should be so it wouldnt slam down on the brake reservoir or stuff like that. After mounting it, I moved everything off the cowl and shut the hood, I don't think it could be any more perfect. The intake horn should fit where I have nothing mounted, hopefully giving me 4" or so clearance in case I want to mount stuff to that spot in the future. I want to get rid of that power distribution box but that will just have to wait. Going to try and get a lot done tomorrow.

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ISX

Holy Cow dude... That's going to be sweet when its done... :thumb1:

Wanna do a 24V next? :lmao::lmao2:

I don't even wanna look at a 24V :moon: Keep your mess to yourself :evilgrin:

I finally got the front end completely pulled in, Horns/Air Bags/Headlights/Turn Signals/Fog Lights.. That was the hard part so now I just have the easier stuff to do. I do still have to mess with the sensors on the engine, figuring out how to route them. I'm gonna kick myself to work on it every night and hopefully it will be done by a week from now. I really like how it is turning out so far.

http-~~-//www.youtube.com/watch?v=5AsxLrjFemQ

Oh and the bushings/grommets with the wires coming out worked good because I kept everything together, so each thing is in it's own category. They are drilled out like a pyramid, so here is what I mean:

Posted Image

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Wild and Free

Heat shrink will neaten it up a lot vesus electrical tape. I Suppose you bought a 50 lb bag of butt connectors to do it all with too.:lmao: Just a joke but hopefully not.:doh:

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ISX

I don't even own butt connectors :lol:

Basically I am cutting the wires, and adding/removing as necessary. So the PCM wires are really long so I will cut them down, but the wires from the cab to the fuse box are short so I have to make them longer.

Everything is soldered and heat shrinked. The ends of the braided sheath are also heat shrinked so it will never "unbraid". The blue tape is just there temporarily to keep them from unbraiding.

I got 200FT of the braiding and 12ft of 3:1 3/16" heat shrink. I got a deal on some 14 and 12 gauge wire so I have 500FT of 14 and 12, black and red, or 2000FT. Hope its enough :lol:

I got some pics since the videos aren't the greatest.

In this pic (airbag sensor) you can see what I have been doing. I have a couple inches of the stock wiring, then a solder/heat shrink, then my wire. You can see where the heat shrink is, right before the wire turns into red wire.

Posted Image

Wires coming to common location by drivers side firewall. White spots are dirt from a battery I stuck in there to test everything :doh:

Posted Image

Wire going into the bushings.

Posted Image

Another shot of the wires by firewall.

Posted Image

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ISX

Going to try and get it done this weekend. Already off to a bad start. I have been wondering what to do with the 3 connections on the drivers side firewall and decided to get rid of them entirely as some wires in each one just go straight to the fuse box wires and are spliced into it down there, so I am cutting them off and running everything straight up to where they need to go. The problem came when I started tracing out wires and couldn't find a bunch of them on the PCM side. They would be on the fuse box side but not come out on the other side of the connector. Upon closer inspection, dodge actually wires up crap I don't have like a trans relay, but they stop wiring at that connector, the relay is there, the wiring is there but the other side of the connector doesn't even have the contacts in for it. Which means I have a lot of wires going to nothing since I don't have an automatic. I'm ripping them out, relay and all. I have already ripped a lot out, interesting how many wires go to nothing.

--- Update to the previous post...

Not going to get done this weekend lol. I forget how hard it is to figure out where to run everything. The wires are spliced in bad spots and other wires are just a pain to figure out where to route. I did get rid of a couple relays that I think went to nothing. Got rid of the fuel heater relay as well since my heater contacts are fried.

I thought I would get rid of a bunch of wires by running the ones from the 3 big connectors into the fuse box that had been from the PCM, so basically the PCM to fuse box wires. Turns out there are only a few. Got them out of the way. Still got a lot to do. It's been over a month now that I haven't heard that thing start :stuned:

--- Update to the previous post...

Figured I would do this for the nonbelievers lol. I will show that all you need to run a 12V is a few seconds of 12v power. I just jammed a wrench into the shutoff solenoid to hold it up. Woulda started faster if my idle wasn't so low, normally I step on the pedal a little. It also hasn't been started in a month.

http-~~-//www.youtube.com/watch?v=QjyzfZMEMRc

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ISX

Got some more done today. I have been putting this part off because I didn't know what to do with it. I think it turned out really nice.

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ISX

Sooo, uhh, I'm still working on this thing :ahhh:Was gonna get it done yesterday but that didn't happen. The more I look at it the more I want to stop and redo it all a completely different way, but I want to tear the dash apart too. It's still a lot better than stock, but now that I know how it is all wired I would like to do it a different way. I will finish this way up though and wait for another time. It would be so nice to have an identical truck to do that I could do the final draft of work on, save all the rough drafts for my truck so I could have a flawless other truck. This might not look too bad when it's all said and done and I get it all hidden.

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Wild and Free

OH NO.........I was hearing the phrases "I Hope" "I Think" and "It Should" a few times in the last video. Did I sense the Aprehension level rising and confidence level is falling a bit?:ahhh:

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Mopar1973Man

OH NO.........I was hearing the phrases "I Hope" "I Think" and "It Should" a few times in the last video. Did I sense the Aprehension level rising and confidence level is falling a bit?:ahhh:

I understand when you get into a large project like this and it takes longer than you planed and then not having the time or the money to finish it your timeline tends to make these comments come forward... But I got faith in you ISX keep going! :hyper:

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JOHNFAK

I understand when you get into a large project like this and it takes longer than you planed and then not having the time or the money to finish it your timeline tends to make these comments come forward... But I got faith in you ISX keep going! :hyper:

That boy aint ever failed on anything 12v related :) Keep going hard fella :) That wiring and sheathing looks nice :)

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ISX

I have confidence that it will work and run and everything as it should, but the wires are just splicing too much. Dodge puts so many wires together that it is almost impossible to have wires that go from one thing to another. Instead they go from one thing to another making several pitstops. I have tracked all the wires down, fixing all that BS as best I could but some things are just tied into too many things. I know what needs to be done to fix it all but it will take a lot of time. I think I will just lower my standards a bit and call this good. I am going to be doing a lot of dirt bike riding and I already had to have the guy I ride with pull our trailer this last weekend. I have another one this weekend and I need my truck for it. I am so close to being done now, the hard parts are pretty well done. Well there wasn't really any hard parts, just parts that look crappier than others. I can hide it all but I don't believe in hiding stuff, I think the stuff behind the scenes should look just as good as the stuff in front of the curtain. Anyways I just got back from the dirt bike trip and will work on it little by little all week and hopefully be done by sunday. Thanks for all the support guys! It is definitely a time problem. I have money since I am working so much that I don't have the time.. I could have had it done weeks ago but I get bummed out on stuff that could potentially not go how I want (like this). I'll get it done though and hide it all and it should all be good. Not perfect, but good.

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Wild and Free

Yeah don't sweat the small stuff. its ok if you need to step on the brake pedal to turn on the high beams or flip the dimmer switch to activate the wipers or push the cig lighter in for window washer fluid you'll figure it all out and learn to live with it.:lmao::lmao2::lol: Years ago I worked for a Komatsu equipment dealership and had the misfotune to get a project much like this one. Had to install a cab riser kit on a pc 400 excavator. youve seen them at salvage yards the ones with the cab way up high. well there are many ecms on them and I had to build and route many ecm harnesses to accomodat the cab riser. There are no kits for that every thing was home made about exactly what you are doing now only on a bigger scale.

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ISX

I've had to track them all down so many times that I pretty well know how every single thing on that truck is wired. How big the wire size on everything is, all of it. So now I can add wiring to my list of things I'm not afraid to do anymore on my truck. I keep doing things like this because I want to know what to do when I end up on the side of the road. I haven't had a single problem with the truck but I am hoping my effort pays off and the whole thing leaves me stranded so I can have a chance to fix it. I don't see why I have to always fix everyone else's stuff, why won't mine break for once :lmao: It's depressing really :lmao2: Bad part is, all I really have left to take apart is basically the p7100. I am a little sketchy on taking all the bolts out of it. I think it is simpler than I am thinking but I don't want it to end up costing me $1000 if I screw something up.

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MnTom

Just remember, the position of the barrels is critical for proper fuel volume and balance.

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ISX

I got it done today. Well not really. I got it to the point that all I got left is the battery cable connections and alternator connection so I just jumpered it all up with jumper cables to see if anything actually worked.Everything somehow worked, EXCEPT, the WTS/WIF/Check Engine/GEN lights were all on, the RPM doesn't work, not sure what else, everything else seemed to work fine. According to the schematics, there is this "sensor ground" that shoots off the PCM to all those things I listed that don't work, well I said hell with that and just ran all of those to a normal ground. I am thinking it needs to go through the PCM for some reason. I didn't think it would matter but I guess it does. Will just have to use dads truck to pull the trailer tomorrow, at least its only 40 miles away. I will fiddle with it through the week and hopefully get it perfected.As for pics, ehhhh, it looks like crap. The wires are all too long, there are a million wires more than I expected.... I might take one later on in the week but I am to the point to where I just threw it together and am awaiting plan B. Now that I know what not to do I can do it right, but I think it will be a long time before I take it back apart, unless I buy another cummins.

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Mopar1973Man
:doh: D'Oh! I could of told you that one about the grounds... :rolleyes: Dang... So close but so far away... The sensor base there grounds on PCM grounds not body gorund. Same with ECM on the 24V truck they base off the ECM ground not body ground. This is why its so critical for grounds to the PCM/ECM be in good condition because the internal ground that the ECM/PCM create are based off them.

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