Thread: TD5 Injector Wiring Loom - oil sealing against oil in the harness issue

Thought I would share this as a lot of the old threads seem to have been lost in the crash a couple of years ago or the pictures in them are no longer displaying due to ImageShack and Photobucket changing their rules.

I purchased my D2a TD5 from Phil (discowhite) in 2010 with 180k km on it. At the time of purchase, he informed me that a few years prior he had replaced the injector wiring loom and modified it so that it will never experience the infamous oil in the harness issue. Fast forward eight years and 100k km later it would seem that he was correct. I've currently got it apart and am replacing the loom, but not because of oil in the harness, rather because the main loom connector plug failed - the plastic became brittle and has separated which left the engine unable to start due to no signal to the fuel injectors:




Anyways, here's photographs of his modifications that I will attempt to replicate in hope of having another long run of trouble free motoring:






There doesn't seem to be any cutting and rejoining of the wiring as I've read discussed in a few threads:



If anyone has any further improvements on these, let me know please.

Originally Posted by onebob

I used Permatex “RightStuff” gasket maker on my new loom about 6 + years ago because it is impervious to automotive oils and fuels and is good up to 230 degrees C from memory. 3Bond is another good one and is a bit cheaper. Tip 1 : on the top of loom plug where the injector wires emerge there is a cover disc with 2 holes in it - lift the disc out and you can see the top of the pins...fill this space to the brim with gasket maker and if you want (i did) snap the disc back in and clean up the ooze. Tip 2: use RTV gasket maker and not regular RTV sealant - its a hot, oily and fume filled environment so you need the RightStuff to be sure of success. I’ll download the pics from photobucket and repost them here if i can remember my login details.

I did the same years ago but used some Wurth stuff brilliant and same or lack of leak