TD5 injector harness - a different idea

Ok since this has been thread mined I thought I might put idea I've had for my defender for when my td5 gets oil into the harness again.

The idea I've had was to fit a deutsch plug in the main harness where it runs next to the head but when fitting strip the wires back about 10mm each side of the plugs and solder both sides and shrink wrap with removing one of the seals on the female plug this should in theory cause a large enough block to stop the capillary action.

we have done a similar thing to Volvo trucks at work that suffer a similar fault and we now end up with an oil leaking plug and not reaching the ecu. Only difference with the volvos and the td5 is that the volvo ecu is higher than the engine so not 100% it will solve the problem on the td5 but will slow the effect.

IMO the only real fix for that would be a quite ugly bodge which means to remove the solenoid plugs from the loom and solder the wires directly to the solenoid pins(beside protecting the wiring from oil ingress) cos IMO the main problem is that the contacts in those plugs are loosing strenght in time due to heat and as oil gets in there it acts as an insulator so the contact resistance is growing... that pulsatory 85V signal to the injectors needs as perfect contact as possible. I removed the fuel pump and measured impulses there at the solenoids with oscilloscope while cranking and seen variations when i just put my finger on the solenoid plug with an old loom... much more stabile with new genuine loom that's why i have this theory

I did this with no issues since. Cost <$5

http://www.aulro.com/afvb/technical-...-once-all.html

I also created a "dome" on top when sealing so no oil pooling on connector. Sorry no pics when I did it.

Quote:

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Originally Posted by nvydvr

I did this with no issues since. Cost <$5

http://www.aulro.com/afvb/technical-...-once-all.html

I also created a "dome" on top when sealing so no oil pooling on connector. Sorry no pics when I did it.

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My new Genuine Injector Harness is on it's way to me and hopefully 15 years on Land Rover have come up with a fix for the capillary action problem.

I thought of encapsulating the connector but my local JAYCAR didn't have the resin but have thought that Fuel Tank repair putty might be an option...... ?

Quote:

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Originally Posted by onebob

My new Genuine Injector Harness is on it's way to me and hopefully 15 years on Land Rover have come up with a fix for the capillary action problem.

I thought of encapsulating the connector but my local JAYCAR didn't have the resin but have thought that Fuel Tank repair putty might be an option...... ?

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Sorry to tell you Land Rover haven't "redesigned the wheel after 15 years", why would they, the vehicles are old now and out of warranty so no longer their problem. It's just a crap design.

They live in hot oil,there is no fix,it's something you have to live with. Pat

+1^^^, no sealing will cure the fact that the contacts in the solenoid plugs are loosing theyr strenght in time, stopping the oil to get to the outer plugs will fix only max. 50% of the problem

Quote:

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Originally Posted by onebob

My new Genuine Injector Harness is on it's way to me and hopefully 15 years on Land Rover have come up with a fix for the capillary action problem.

I thought of encapsulating the connector but my local JAYCAR didn't have the resin but have thought that Fuel Tank repair putty might be an option...... ?

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Here are pics of my "hopeful" solution on my new injector harness. I popped off the disc cap and filled the void underneath with oil resistant gasket goop and refitted the cap. Hopefully it will forestall a return of the problem.
https://www.aulro.com/afvb/images/im...015/08/867.jpg
Below is what the old one looked like....
https://www.aulro.com/afvb/images/im...015/08/868.jpg

...... and below some more pics of the extent of the oil problem. The oil will of course continue to seep out of the external engine loom for a while so I've drilled tiny drain holes in the ECU socket to prevent the oil pooling and causing a problem.

https://www.aulro.com/afvb/images/im...015/08/865.jpg

https://www.aulro.com/afvb/images/im...015/08/866.jpg

onebob, I think that has been tried before, the oil wicks up the wiring, so I assume it enters from the injector connection and runs along the wires. The plug end the wires are crimped to connector lugs, the oil can still wick out of the crimped lug/wire connection.

By putting sealant into the plug end, it may not seal the crimp on the wire to the connecting lugs/
The sealing needs to be better at the injector end.
Hope you have luck with it though.
Regards,
Mario