86.5 Z24i Engine cutout SOLVED!! - Nissan Forum
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post #1 of 40 Old May 2nd, 2010, 04:59 PM Thread Starter
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86.5 Z24i Engine cutout SOLVED!!

Some of you may have been following the saga in another thread.

Recapping, my Z24i has been cutting out around 2500 rpms. It ran fine up to that rpm "limit". I'll spare you the parts I've replaced, time and money I've spent. Turns out the issue was with a buried splice connector in the main harness that feeds power to the 2 injectors. For some unimaginable reason, Nissan engineers spliced the 2 power wires (one for each injector) down to one wire, then about 8 inches later, spliced it back to 2 wires. This second splice was completely corroded and came apart with the slightest tug. I clipped, stripped and crimped them back together and problem solved.

Here's a pic of the bad splice.



Here's a pic of the other splice (sorry for the fuzziness).



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post #2 of 40 Old May 2nd, 2010, 05:07 PM Thread Starter
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Thanks to all of you who've followed the thread, made suggestions and hung in there. A very special thanks to Nissanpartsdept for providing the "silver bullet" that led to the final solution.
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post #3 of 40 Old May 13th, 2010, 01:45 AM
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Done alot of that guys!

Tblue

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post #4 of 40 Old May 14th, 2010, 09:48 AM
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very glad you are back on the road...

thanks for the progress report..


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post #5 of 40 Old May 14th, 2010, 11:17 AM Thread Starter
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Thanks Zane! It even passed smog test today !!
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post #6 of 40 Old May 19th, 2010, 09:58 AM Thread Starter
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Due to a request for some details, I've decided to add to this a bit.

First, the harness in question comes through the firewall on the passenger side then splits. One split runs down the inner fender then splits again into several branches. The pic below shows the harness with a red line. The 2 red circles indicate the approx location of the splices.



Next, there's more than one spice at the location on the right. When I fixed it originally, I only looked at the injector splice. A week later I sliced it up again to check the other splices. You can see what they looked like.



So if you're going in there. Take the time to check them all out!
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post #7 of 40 Old May 19th, 2010, 10:38 AM
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Saudade, I am so glad I was able to shed some light on your problem. I guess sometimes us old farts can remember a few helpful tips lol.

Glad to see you posted the pics for the future. Wish I had had some when I was explaining it to you.


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post #8 of 40 Old May 19th, 2010, 10:53 AM Thread Starter
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Quote:
Originally Posted by NissanPartsDept View Post
Saudade, I am so glad I was able to shed some light on your problem. I guess sometimes us old farts can remember a few helpful tips lol.
As one old fart to another, I too occasionally have moments of genius that always surprises my teenage sons.

Quote:
Glad to see you posted the pics for the future. Wish I had had some when I was explaining it to you.
I knew right where you were talking about. Hopefully the pics will help others.

Again, many thanks!!
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post #9 of 40 Old Jul 15th, 2012, 03:49 PM
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This is exactly what my truck is doing! I just got my truck, and it ran fine for a couple of months. A local mechanic confirmed that fuel is cutting out above a certain rev range. I bet this is going to solve it. Thanks in advance....
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post #10 of 40 Old Jul 15th, 2012, 05:48 PM Thread Starter
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Good luck! Hope this works.
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post #11 of 40 Old Jul 15th, 2012, 07:46 PM
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I hate those splice connectors! Best thing you can do is break out the soldering gun and solder all of those splice connectors for a better and more permanant repair!
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post #12 of 40 Old Jul 16th, 2012, 02:52 PM Thread Starter
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Quote:
Originally Posted by smj999smj View Post
I hate those splice connectors! Best thing you can do is break out the soldering gun and solder all of those splice connectors for a better and more permanant repair!
Yep. I cut and re-spliced all of them with solder and heat shrink tubing.

You can see by the dates, this was over 2 years ago. Truck hasn't skipped a beat since.
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post #13 of 40 Old Jul 21st, 2012, 03:46 PM
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Ok, today I had some time to look at if, finally. I can't find any loose wires anywhere, all the plastic connection blocks look fine. Are the splice connectors inside the harness itself? In other words, do I need to slice open all the bundled wires to find them? I also found a few vacuum hoses that are missing in the area behind the throttle body.

To recap, the engine cuts out very suddenly and completely over a certain rev range. All cylinders stop firing as though the ignition was switched off. When the revs drop, the engine resumes. Revving in neutral, it sounds like you're gunning the engine. Under load the truck bucks.

I took it to a shop, and they confirmed I have spark throughout the rev range, and that it's fuel that is being cut off. THey were stumped, and replaced the fuel filter, which did not fix the problem.

When I found this thread, it seems to describe my symptoms exactly. But I'm a bit stuck. I have attached a few pics. Any ideas welcome.
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post #14 of 40 Old Jul 21st, 2012, 03:48 PM
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post #15 of 40 Old Jul 21st, 2012, 05:22 PM Thread Starter
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Yes, you have to cut open the bundle. Not sure why I don't see it on yours though. Is yours a D21 "HardBody"?

Someone did hack it up. I'd redo those splices.

Follow the harness out of the TB with the red,green white wires showing and see where it goes.

Last edited by saudade; Jul 21st, 2012 at 05:43 PM.
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