I had a problem with cel and rough running that turned out to be burnt wire harness under the right valve cover. It was the one by the oil fill cap. By the way my oil fill cap is chipped and has holes in it. I recently replaced it and was told this is caused by heat. Is that true?

Anyway, when I removed the old harness parts I noticed the connector to the injectors had a rubber device to seal out oil from the connection. I got my wire harness and VC gasket from Ford and they didn't include the rubber gaskets. I tried to use the old ones but they were basically useless so didn't use any.

My question is am I going to have a problem with oil getting in the connector and shorting it out the injector?

 

I had the same situation and I bought the connector repair kit from Ford and new terminals (pins)from Dion International. A search on FTE for the glow plug or injector harness connector repair kit should get you the part numbers.

The repair kit has the rubber boots.

I went a step further with my repair. I stripped all of the wrap and split loom cover back as far as possible and then placed two layers of heat shrink tubing on each branch of the harness - you can only do this if you are repairing or replacing the connector. Then after repair the pins I heated the tubing - first a black tube then a red tube- the red tube was 1/2 the length in one diameter and 1/2 in the next larger diameter so I could slip it out of the way while I shrank the black tube. After that I installed the replacement connectors and then sealed the connectors to the harness wires using marine grade liquid electrical tape. Then I placed split loom wire protector over the heat shrink and sealed it with liquid electrical tape.

The next person to try to break open the harness will have a devil of a time. - its a tuff job on my truck anyway. If its me next time I'm going to rebuild the entire harness anyway so it won't bother me how well it is sealed up. I figured that that since I went to the excruiciating detailed and difficult task of replacing and repairing every pin and every connector, I should insure my investment with a very good seal.

The truck is a cutaway van so the task was done sort of laying across the back of the engine with very little head room. Very painful. The turbo and intake and fuel pump were removed.

 

Joseph, if you get a moving blanket or some other type of padding, lay that across the engine and lay on it. Mucho more comfy.

Rog

 

Q-By the way my oil fill cap is chipped and has holes in it. I recently replaced it and was told this is caused by heat. Is that true?

A- YES

 

Kawa -Rog, we think alike. I have a moving pad that is now part of the truck tool set. It still hurts to press a shoulder into the lift points.