Electrical - Relays and Grounds - Removing twisted and taped splices

These items were addressed today (and yesterday):

1. Repaired last splice for wires going to relays.
2. Test fired engine and idled for a while.
3. Replaced main ground strap from pass. side exhaust manifold to firewall.  It was still just twisted together.
4. Repaired (butt splice) ground from relays to drivers side firewall. 
5. Terminated (yellow terminal ring on drivers side firewall) and attached ground from wire harness to firewall that was not connected.  This was connected previously, prior to engine removal.  This ground might also need attention where it goes into the harness but I could not get at it.  It would have been easy to repair when the engine was out.



EGR Valve Connector:
Plastic is missing at bottom where spades go into connector.

6. Repaired (butt splice/terminal ring) ground wire from passenger side exhaust manifold to engine harness.  This ground might also need attention where it goes into the harness but I could not get at it.  Again, it would have been easy to repair when the engine was out.



EGR Valve Connector:
 Retaining clip is broken 

7. Four wires on EGR valve connector are still just twisted and taped.  Repairing this was deferred because the connector is in such poor condition.  It should be replaced.  It can be purchased from rockauto.com for ~$30.
8. Properly mounted relays on drivers firewall.  They were laying on fender well and were susceptible to wear from vibration.
9. Engine harness was resting on exhaust manifolds on both sides of engine.  This would, at best, cause a wiring failure, at worst, a fire.  I supported the harness on the passenger side with a zip tie to the ignition coil mounting bracket.  Then I saw temp rating on zip tie package.  Didn't think it was high enough so found 12AWG house wire roll and used to support the harness.  Under hood temps can get near 400 deg F.  On the drivers side I used one of the wiper motor mounts to support the harness with 12AWG wire.  This should minimize wear from vibration and heat.
10. Fired it up and connected TunerPro RT  software (version 4 on old laptop) to car to try and monitor engine - hoping to get reason for 'Service Engine Soon' light.  Couldn't monitor but something wasn't quite right.  Need to do more research.  More on this later.  
11. Fed and watered the chickens (Friday and Saturday).