 | Home > Td5 > Injector harness sealing |
 
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| mk1collector Member Since: 17 Sep 2009 Location: West Yorkshire Posts: 6769   
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Having searched for how to's on sealing my injector harness because oil had reached the ecu again, info seemed to be few and far between and not very many pictures were available so I thought I'd put together a little guide so anyone who needs it gets a rough idea of what's involved. Firstly I'd like to say I'm not a mechanic and will take no responsibility for people having problems from following this guide
 So first get your new injector harness in front of you (I'd recommend either genuine or oem only) it should look like this.
 Click image to enlarge The five black plugs that clip on to your injectors need removing first and this is done by lifting the little "tang" at the back of the plug and sliding off forwards to look like this. Click image to enlarge Also the metal top cover of the plug that goes through the head needs levering off being careful not to damage any wires. Click image to enlarge Once the covers are removed you need your sealer. The sealer should be both oil resistant and none conductive so a little time should be taken to research which sealer is best at the time you do this job as sealers change all the time. Firstly I clip the top of the white plugs that the black plugs were removed from so the back of the wires are visible Click image to enlarge aply a small amount of sealer so the bare section of wire is covered and then close the top of the White plug fully so the sealer is contained Click image to enlarge Now sealer needs to be applied to the top of the larger plug making sure the sealer goes all around the wires and into the top of the metal terminals. Click image to enlarge Ray My build thread http://www.defender2.net/forum/topic17615.html |
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10th May 2015 12:16pm |
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| mk1collector Member Since: 17 Sep 2009 Location: West Yorkshire Posts: 6769
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While the sealer is stil wet replace the top of the large plug and wipe off any excess sealer that has squeezed out of any of the plugs
Click image to enlarge I let the sealer set for a couple of days before replacing the black plug ends just to be sure nothing would stick together. After everything was set I fitted the harness and cleaned out the engine bay plug (which connects to the new harness) four or five times with electrical connection cleaner and left to fully dry before reconnecting. The red plug at the ecu will also need cleaning with electrical connection cleaner every couple of days for a week or two just so all the oil has gone from the whole loom. Mine has been on for 6 months now and works perfectly and hopefully should be fine from now on. It probably doesn't need sealer at both the big plug and the five injector plugs but I figured if I do all while its out there is less chance of any oil getting through. Hope this helps  Ray
My build thread http://www.defender2.net/forum/topic17615.html |
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10th May 2015 12:28pm |
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| Alien Member Since: 18 Jan 2015 Location: Bacchus Marsh Posts: 230 
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This is the same way I did my injector harness on the Disco and got 3 years out of it before selling it off as a non runner(timing chain issue).
I strongly recommend doing the round big plug as oil does sit in it when running, some new harnesses have a clear filler in them. |
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10th May 2015 12:52pm |
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| taazzukcb Member Since: 30 Aug 2013 Location: Derbyshire Posts: 663  
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A few people have done this and whilst it doesn't stop it, it slows it down, so saves buying them just as often!
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10th May 2015 7:19pm |
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| Anderzander Member Since: 08 Feb 2011 Location: Lancashire Posts: 1000
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I read of someone doing this with Vaseline to good effect
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10th May 2015 9:15pm |
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| Screbble Member Since: 26 Apr 2015 Location: Lancashire Posts: 2102 
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Excellent post Ray, thanks. I've sealed the new harness/plug as per above ready for installation shortly. It should help stall the oil transmission. That said, there's hardly a trace in the red plug. Still, it's worth doing for the minimal cost. A couple of questions. 1. Does the new rubber head/rocker cover gasket go on 'dry.' I assumed it does. 2. Do/should you have to replace the sealing washers on the 13 cover bolts? Cheers, Will |
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16th Sep 2015 7:58pm |
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| taazzukcb Member Since: 30 Aug 2013 Location: Derbyshire Posts: 663
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You need a bit of sealent in the corners of the half moon. That's the only bit that calls for it.
My rockers been off many many times and I've never changed the seals on the rocker cover bolts. Don't see the need to . Should be fine! |
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16th Sep 2015 8:45pm |
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| mk1collector Member Since: 17 Sep 2009 Location: West Yorkshire Posts: 6769
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As taaz says above
Ray
My build thread http://www.defender2.net/forum/topic17615.html |
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16th Sep 2015 10:30pm |
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| sonnysullivan Member Since: 09 Sep 2017 Location: bermuda Posts: 4 
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hey all, thanks for the great forum! i've been lurking here for a couple weeks reading as much as i can about all things defender. i hate to revive an old thread but i can't start a new one yet. i've been doing lots of research on the injector harness which all seem to agree that it's only a matter of time before the oil flows through them! on another website i read that the problem was solved from model year 2002. can anyone confirm this? if not, is there a visual difference between the old part and the revised part? does the revised part have a new number differentiating it from the original faulty one? thanks in advance gents.
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5th Oct 2017 9:04pm |
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| mk1collector Member Since: 17 Sep 2009 Location: West Yorkshire Posts: 6769
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Mines a 2004 and it still happens (well not to me now as I sealed the harness) are you sure your not thinking of the head dowels being fixed from 2002? Ray
My build thread http://www.defender2.net/forum/topic17615.html |
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5th Oct 2017 10:16pm |
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| mk1collector Member Since: 17 Sep 2009 Location: West Yorkshire Posts: 6769
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Also it's easy to check if you have oil at the red plug on the ecu to find out if you have a problem. Ray
My build thread http://www.defender2.net/forum/topic17615.html |
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5th Oct 2017 10:18pm |
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| sonnysullivan Member Since: 09 Sep 2017 Location: bermuda Posts: 4
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thanks, definitely injector harness, not dowels. so even the updated part fails in the same way? i guess i'll just assume mine hasn't been corrected. i'll buy a new one and seal it myself.
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5th Oct 2017 10:26pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17382
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I don't think that JLR ever fixed this problem, they just made it slightly less bad!
I sealed the harness on my 2002 Disco and it's been good for 180,000 miles since. The main problem is the connector where the harness leaves the cambox, this functions as a sort of funnel to direct oil into the outer connector, from where it tracks down inside the insulation of the individual wires. |
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6th Oct 2017 7:25am |
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| sonnysullivan Member Since: 09 Sep 2017 Location: bermuda Posts: 4
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seems the permanent fix would be to vent the crank case to the air inlet just in front of the turbo.
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6th Oct 2017 3:08pm |
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