I hear you on "dreading" the dis-assembly. That is why I tell people to get the DieselSite upgraded HPOP. It is your best bet at reliability. Many OEM (re-manufactured) HPOPs have failed "out of the box". Bostech (and Bosch) has a TERRIBLE record as does OReilly's HPOPs. Lifetime warranty is laughable when you have so much labor involved. I wonder if that insulation you found was from a rodent .... ?? Yes, a broken (or unplugged) FICM connector can cause a no-start and can cause sudden engine dying.