When he cut the wire's he pulled the wire out of the plastic connector and snipped the end off, so there is plenty of wire.

It'll be Saturday before we get back on it and we'll see what happens.

 

Alright here's an update:

Bro in law had to work Saturday, wasn't able to do anything with it.

I stopped by today and he had the '03 Intake Manifold on the '04 motor, the connection he cut the first time was the main wiring harness on the truck for all of the connection's on the top of the motor: coil, sparkplugs, etc....

Since the connector on the wiring harness was gone he had to cut the connector on the intake, he wired them by color being it's all '03 stuff, and now we have spark but it won't quite turn over, but it damn sure tries

First, he's almost of out gas and what's in it is fairly old, could be an issue.
Second, there is a plug behind the A/C on the bottom in front of the intake manifold (driver side), his '03 wiring harness has no connection for it, the '04 does but it's run into the main harness so I can't tell what it's for. The digital camera took a dump or I would post a picture for reference.

I'm downloading the '04 FSM now to see if I can figure out what connection he's missing.

Also, since the '04 has an EGR valve and the '03 does not, should we hook up the tube since there's a port open on the block or just leave the tube off?

I know the '03 PCM can't control the EGR but will that not being plugged up be an issue?

Thanks for your help!

Edit:

I've looked through the '04 FSM and I can't find anything about the plug we're missing, any help would be greatly appreciated.

 

That should be the one that goes to the top of the EGR.

 

So what would ya'll recommend we start looking at for the no start issue? We have fuel and spark, and it dang sure tries to start, but doesn't catch.

 

No codes at all? You're positive he wired the intake harness correctly?

 

No code's to speak of.

I didn't look at the wiring myself, but I'm confident he wired them right, but we can double check.

Is the EGR on the '04 motor gonna be an issue?

 

EGR shouldn't be an issue since you're using the 03 pcm. You can get a block off plate from shophemi.com and get rid of it all together. That plug you were talking about earlier, in front of the intake manifold, behind the ac, and drivers side was it just the coolant temp sensor? It should still start without it though... egr is passenger side front of cylinder head.

 

That's good to hear about the EGR.

I'm not sure about that plug, I looked through the '04 FSM and didn't see anything referring to it, looked at some electrical diagram's of the motor online and nothing listed what it was.

Whatever it is his '03 wiring harness has no connection for it.

Did the location of the coolant temp sensor change between '03-'04? If it did change that would explain why there isn't a wire close by for it.

Edit:

The picture on page 317 of the '04 FSM shows the coolant temp sensor standing up, the plug on the motor is on it's side facing the driver side fender.

 

Here is my '06 hemi motor sitting in my garage, you can see the coolant sensor there, shiney and bronze. Its laying down. On my 4.7, however, the sensor is standing up, but its in the same general location.

I can get any pics of the 06 hemi you want, I have a main harness from an 05 too I can take pics of. I just don't have an intake harness.

 

Oh, and its also possible that they routed the coolant sensor wiring throufgh the main harness vs the intake harness, depending on the year. For instance, my 05 main harness has a coolant temp plug, but the intake 4.7 harness has it.