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Thread: How do you repair glow plug connectors

  1. #1
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    How do you repair glow plug connectors

    So I have ran into a problem...

    I'm currently repairing a leaking head gasket on my Land Rover Discovery 2 TD5, most things have been going well; I checked the cylinder head for any warping and it is well within the tolerance, I have been deep cleaning the valve ports and the intake/exhaust manifolds. However, when I removed the glow plug connectors the rubber boots just disintergrated and in one case one of the connectors has completely broken off the wires. The wires are in good condition where they connected and it appears the connection just came off the ends.

    Does anyone know what type of connection is used on the end? My research so far has led me to believe that female bullet connectors may be a suitable replacement, but I wanted to double check to be certain.

    Any advice would be greatly appreciated. I am intending to remove, clean and then re-wrap the entire harness with cloth tape and braided wiring sleeve as the original plastic stuff has just disintegrated in alot of places.

  2. #2
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    I believe the part number for the harness is ERR6066. Not sure about fixing the plugs. Seems like it could be ok, but the TD5 ECU is a little, err, sensitive... Personally, I'd have a go.
    ​JayTee

    Nullus Anxietus

    Cancer is gender blind.

    2000 D2 TD5 Auto: Tins
    1994 D1 300TDi Manual: Dave
    1980 SIII Petrol Tray: Doris
    OKApotamus #74
    Nanocom, D2 TD5 only.

  3. #3
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    My nephew recently had the same issue. Doing HG and found all glow plug wires failed or close to it.

    He and his dad just repaired each wire as required. That is, the failed connectors were soldered onto the wire, any dodgy looking wire got a sheath of heatshrink.

    I saw online(maybe youtube??) someone used a VW glow plug loom. The spacing is close to identical. I tried to find the video for nephew to see it too, but for the life of me can't find it.
    Arthur.

    All these discos are giving me a heart attack!

    '99 D1 300Tdi Auto ( now sold :( )
    '03 D2 Td5 Auto
    '03 D2a Td5 Auto

  4. #4
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    ERR6066 should be available from UK I was able to fix mine with heat shrink. Regards PhilipA

  5. #5
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    Quote Originally Posted by Tins View Post
    I believe the part number for the harness is ERR6066.
    ERR6066 is the glow plug's p/n, there are many glow plug harness repair connectors available, they are quite common and the same for a huge variety of engines, for the Td5 is good a connector which works for any of the vehicles shown in the compatibility list here Just a moment...
    Discovery Td5 (2000), manual, tuned

  6. #6
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    This is not really helpful in regards to repairing your problem, but, I don't think the glow plugs worked in our old 01 D2 for the entire time we owned it. Our mechanic at the time said, I can fixed them, but you don't really need to unless it becomes hard to start, which never happened.
    Cheers Baz.

    2011 Discovery 4 SE 2.7L
    1990 Perentie FFR EX Aust Army
    1967 Series IIa 109 (Farm Truck)
    2007 BMW R1200GS
    1979 BMW R80/7
    1983 BMW R100TIC Ex ACT Police
    1994 Yamaha XT225 Serow

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