Thread: TD5 Injector Loom attempt at sealing

Hi all,

A recent attempt at diagnosing why my Disco was shuddering (and eventually dying completely) prompted me to check the oil in the loom problem. Sure enough there was lots oil at the plug. So I unplugged it and took out the ECU, opened up the ECU to check there was none inside (there wasn't), gave the plug a clean and put it all together. Long story short, this didn't fix the problem, nor did replacing the MAF sensor after it logged high. I should have cleared the error before I drove to the mechanic but at least I have a new MAF sensor and while it was being serviced I asked them to order a new loom and gasket for me.

Once the Disco died completely I did a bit of research and decided it was the fuel pump with a test given to me by my mechanic. This did fix the problem but I still wanted to replace the loom as after only about a week there were traces of oil at the plug.

A member here mentioned they had stripped the individual wires and found oil even at the cores, and the only way to fix this would be to solder them. So I pulled apart my loom and had a look. Sorry about the focus of the pictures I was messing around with the manual focus on my camera and the screen is old and tiny.

This is what the individual wire ends look like once you pull everything out of the plug:


As you can see they are just crimped and if any oil got to the plug it would be wicked freely through the wires.

This is how I soldered it:


I added a dash of sealant to the rear of the crimp:


The loom I bought was one that had already been sealed at the main plug (sourced from MR Automotive I believe) but I wanted to add a little extra to be sure:


I followed the instructions from here, www.discovery2.co.uk / Workshop /Injector Harness, and when he says remove all the washers DO IT! Mine were somewhat stuck but when I took the cover off 3 fell off. I found 2 and spent a total of probably 6-8 hours looking through the engine bay and the cylinder head for the third one. I ended up buying one as I couldn't find it even with a little magnetic probe. Very annoying mistake.

One thing I would like to ask, my cylinder head and rocker cover were no where near as clean as in the tutorial. There was a thin black film that looked like it would come off with some scrubbing. Should I be worried about this and should I spend some time cleaning it off?

Also, I used Sellys 100% RTV silicone which, looking at the tube I assumed would be fine as it mentions using it to replace gaskets. But after I finished I noticed the back says it shouldn't be in contact with petrol or distillates. A little late now but I hope I haven't shot my sealing attempt in the foot.

Just finished soldering the conduits the other day. There are two and luckily for me the rubber heat shrink had kept oil away from the crimp so it was just a matter of removing the heat shrink and soldering.

This is what the conduit looked like:


This is the two soldered:


The whole process was much easier the second time around since I didn't lose any washer this time Although I did strip one of the bolts holding the acoustic cover and had to melt a section off to rip it off

P.S. This is what the inside looked like. Not sure if it would be worth cleaning.