DIY Fuel Injector Harness repair?

[daverdfw]

Curious if anyone has done their own Fuel Injector harness repair? Down here in TX the heat has absolutley killed my plastics and when i upgraded new injectors the plastic seperators broke, and one of the boots is melted, curious if anyone has taken some of the 034 motorsport wire looms and redone all of this to protect it from the heat.

here are some of the things i am looking at.

http://www.034motorsport.com/wiring-...l-c-57_60.html

[elewsader]

I keep putting these connectors in a basket but then close out the tab.

The Bosch pigtails, with boots, and heat resistant sheathing should be all that you need. I repaired my harness a couple months back, but I do intend on completing a new fuel injector harness in the coming months.

[MikTip]

http://www.jimellisaudiparts.com/sho...rimLevel=19028

[MikTip]

http://car-part.com/cgi-bin/search.c...ey=&userPage=2

[daverdfw]

my issue with a used harness is its still the same crappy plastic that gets brittle and breaks, i am debating doing the route where i use new pigtails and just solder them myself.

[texasboy21]

Bumping this thread for some assistance. I purchased some Bosch EV1 repair harnesses from these guys: http://www.diyautotune.com/catalog/f...-ev1-p-48.html

and need help identifying the power and ground on the injector harness.

[Seerlah]

Word of advise, DO NOT solder. Use crimp butt connectors (Radio Shack has a draw of goodies. And in this draw you will have any size you need). Reason being is one wire is a constant 12v+, which comes from a fuse on your panel driven by the fuel pump relay and out one of the colored connectors on your harness. The other is a pulsed ground from the ECU to drive the injector with accuracy (amount of fuel to spray). If your solder introduces more resistence to the fuel injector pulsed ground, I would expect your fueling to go awry.

I recently fixed injector one on my harness. I have a spare harness laying around. I just cut off one from my spare with slack (made sure no cuts or corrosion on the pig tail), used butt crimp connectors, "remembered what colored wire had to go to what" (spare parts harness had injector one missing, so used a different cylinder injector with different colored wiring), heat shrink, and good to go. I want to wrap the wires in cloth tape too, but have been lazy.

[texasboy21]

Word of advise, DO NOT solder. Use crimp butt connectors (Radio Shack has a draw of goodies. And in this draw you will have any size you need). Reason being is one wire is a constant 12v+, which comes from a fuse on your panel driven by the fuel pump relay and out one of the colored connectors on your harness. The other is a pulsed ground from the ECU to drive the injector with accuracy (amount of fuel to spray). If your solder introduces more resistence to the fuel injector pulsed ground, I would expect your fueling to go awry.

I recently fixed injector one on my harness. I have a spare harness laying around. I just cut off one from my spare with slack (made sure no cuts or corrosion on the pig tail), used butt crimp connectors, "remembered what colored wire had to go to what" (spare parts harness had injector one missing, so used a different cylinder injector with different colored wiring), heat shrink, and good to go. I want to wrap the wires in cloth tape too, but have been lazy.

My replacement pigtail has one red wire, and one black wire. How can I determine which wire is the constant 12V and which is the pulsed ground? (ASSUMING, my red wire is the constant 12V and the black the ECU controlled ground)

[Seerlah]

Not in the mood to look it up in my Bentley (those diagrams can get confusing sometimes too). But just follow which color wire comes off your stock harness to pin one and pin two on the connector (write it down in case you forget). Butt connect the wires accordingly for the new plug. Also, the wire colors are different for all eight wires.

[texasboy21]

Not in the mood to look it up in my Bentley (those diagrams can get confusing sometimes too). But just follow which color wire comes off your stock harness to pin one and pin two on the connector (write it down in case you forget). Butt connect the wires accordingly for the new plug. Also, the wire colors are different for all eight wires.

Genius, butt the wire off pin one to pin one on the new pigtail. Hopefully I can have it finished up tomorrow morning at the latest.

[Seerlah]

Good luck! Update how things turn out.

[Lysergik]

I am getting ready to replace my fuel injector harness as well. I wasn't aware that the negative wire sent a pulse signal so now I am wondering if my idea to create a detachable harness is going to work.



Here are the connectors and terminals I plan on using, will this setup create too much resistance or interrupt the pulse signal?

[Seerlah]

Nope. You create resistance by any type of load (switches don't count) or cause an area where the voltage would have a difficult time passing through (ie burn mark from solder, short, etc). Your idea should work. Don't see why it wouldn't?

[texasboy21]

Here a some pics of my install which included OEM fuel injector cups, fresh o-rings and clips for the injectors, and new injector harnesses with 6" leads.

http://www.diyautotune.com/catalog/f...-ev1-p-48.html

Cylinders 2 and 4 looked like this (cyl. 2 shown):

[Seerlah]

Looks good . Think I'm going to do this myself. Bookmarked the page for the pig tails.

[Lysergik]

Nope. You create resistance by any type of load (switches don't count) or cause an area where the voltage would have a difficult time passing through (ie burn mark from solder, short, etc). Your idea should work. Don't see why it wouldn't?

Cool, just wanted to make sure before I cut the original harness off.

[Lysergik]

Here a some pics of my install which included OEM fuel injector cups, fresh o-rings and clips for the injectors, and new injector harnesses with 6" leads.

Looks good, I plan on doing mine this weekend. What type of wrap did you use on the wires? I have the high heat wiring tape from IE, but may want a little more protection.

[daverdfw]

I soldered mine and I have had no issues at all. I made sure that both wires were touching and just used the solder on top of them. The pink is heatsrink tubing, I wrapped it with electrical tape after. Am debating replacing it with something a little better like what was posted above.

[texasboy21]

Looks good, I plan on doing mine this weekend. What type of wrap did you use on the wires? I have the high heat wiring tape from IE, but may want a little more protection.

I used a cloth like heat wrap tape, then the plastic tube thats rated up to 300*. Its not permanent; I am looking for something "heavy duty" for both my fuel injector and coilpack harnesses.

[Seerlah]

Jumped on the band wagon and got this done last night (pics will come later). Wrapped it in electricians vibration cloth tape, due to neither Home Depot nor Lowes carrying Gaffers cloth tape (disappointment). Want to make it prettier/cleaner, but not quite sure what route I want to go about it.

[texasboy21]

Jumped on the band wagon and got this done last night (pics will come later). Wrapped it in electricians vibration cloth tape, due to neither Home Depot nor Lowes carrying Gaffers cloth tape (disappointment). Want to make it prettier/cleaner, but not quite sure what route I want to go about it.

Im looking for something pretty too. Let me know what you find, and I will do the same.

[BARRY]

Here a some pics of my install which included OEM fuel injector cups, fresh o-rings and clips for the injectors, and new injector harnesses with 6" leads.

http://www.diyautotune.com/catalog/f...-ev1-p-48.html

Thanks for the link! I ordered a set of 4 to replace my cracking factory harness.

[texasboy21]

Thanks for the link! I ordered a set of 4 to replace my cracking factory harness.

Youre welcome!

[Fast4esT]

will these plugs EV1 plugs not work with Siemens 630s?

[Seerlah]

Siemen 630cc injectors use Jetronic connectors, which the stock harness uses. So yes, they will work.

But from personal experience, those injectors are not that good. I mean they work, but the fuel distribution is not the best by a long shot. I ran Siemen 630cc injectors and swapped them out for Bosch EV14 630cc injectors, nothing changed in the tune besides injector constant iirc (I did not tune my car, but a forum member did). Only reason for the change was I wanted a smoother engine, and swapping out those injectors did the trick. Even the rough starts (subjective) went away and she fires up much more smoother. That was just on the engine start up. Drive-ability is night and day difference apart with the different spray patterns the Siemen injectors provide vs Bosch.

I originally butt-connected Jetronic EV1 pigtails when I ran the Siemen 630cc injectors. When I swapped in the Bosch EV14 630cc injectors, I used the (non-pigtailed) adapters and they would occasionally cause me misfires mid-travel where ever I was. Got annoying having to pull over, pop the hood, and wiggle the connection (just the adapter area) just to make the misfires stop. Got annoyed and ordered EV14 pigtails. Took off the EV1 pigtails I butt-connected to the stock harness and butt-connected EV14 ones in. Misfires went away and have been fine ever since. So now my harness is configured directly for EV14 connections.

Pics of my setup and an idea of what you can do to make it cleaner. I tucked that section of the harness under the intake manifold to give an illusion of a wire tuck. And if you ever have to do the ignition coil section, you can decide on what to do to route that section also to the cold side of the motor, which will prevent it from drying/burning out again.

[DPDISXR4Ti]

I've rebuilt several fuel injector harnesses over the years and always soldered the new pigtails in. Never any issues. Maybe I've just been lucky?

Is there a stock application that uses EV14 style fuel injectors of same output as stock? Just something to keep in mind for junkyard roaming days.

[slacktide]

The real issue with soldering is that it introduces a brittle/hard spot in the wire run. If the wire bundle is well supported and does not flex or vibrate during operation or maintenance, this problem is mitigated, but you have to think and plan ahead. In general I prefer a quality crimp terminal and professional crimping tool, but I ain't skeered to solder if it makes sense for the the application. It beats wire nuts.

[Gosser]

I used a hard conduit from a 4.2 to keep all the wiring nice and tucked away:


It was tight packing in all the wires, and the front cam position sensor is routed through it as well. I ended up soldering new generic injector pig tails in to my bosch 550s, and it has been perfect since. The only thing I do not like about this, is that the conduit does not clip into place around the connectors I purchased, and I had to trim it a bit, but its snug. If I were to do it again, I would try to find the appropriate injector pigtails that fit-into this conduit, and work with the injector.

[Gunnarrrrr]

Might as well crimp on some EV14 pigtails instead of EV1's

[eljay]

FYI folks, Ford Fiesta (and maybe Focus too) uses the EV1 connectors, so you can snip the entire harness and create a connector to your harness at the end for a clean install.

[JDCinATL]

I replaced mine about a year ago with an ECS harness and fought with the supplied crimp tool BIG time. Never did seem exactly perfect, now I am feeling some slight misfire in low rev range, thinking about ordering more pins and soldering the connections when I pull the motor out to do the build swap come fall. My problem is sourcing the proper pins at an affordable price. Anyone know the part number? Also seems that the signal wire is way too small for the pin crimp end. Tried to double the wire during initial install but wasn't happy with it. Could be part of the issue now.

[A4SoftWalker]

I replaced mine about a year ago with an ECS harness and fought with the supplied crimp tool BIG time. Never did seem exactly perfect, now I am feeling some slight misfire in low rev range, thinking about ordering more pins and soldering the connections when I pull the motor out to do the build swap come fall. My problem is sourcing the proper pins at an affordable price. Anyone know the part number? Also seems that the signal wire is way too small for the pin crimp end. Tried to double the wire during initial install but wasn't happy with it. Could be part of the issue now.

ECS crimper and pins are crap for the broad spectrum of wire guages used. Also the proper CLOSED barrel crimper is actually 2-4 times more expensive than the improper open barrel crimper included in the kit. I actually have the business end sitting in my garage. After install I was still missing so I ended up going with the USP coil pack harness. Re-pinned all the way back to the ECU. Works like a charm. Started right up first try and smoothest its run in a while.

I wish they will come up with a fuel injector harness kit as well.

[Ben.Nesheim]

just wanted to add i found this as a replacement 12 pin connector for the ecs ignition wiring harness kit. exact fit looks just like the one that came with the ecs stuff. https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

[DPDISXR4Ti]

Might as well crimp on some EV14 pigtails instead of EV1's

Totally agree. I've got three different vehicles in my garage right from the 80's / early 90's that I've upgraded to EV6 injectors. PSA... EV6 and EV14 injectors use the same quick-connector.

So again I'll ask... What is the output on our stock injectors? Once I know that I'll find a comparable output EV14 injector.

[DPDISXR4Ti]

FYI folks, Ford Fiesta (and maybe Focus too) uses the EV1 connectors, so you can snip the entire harness and create a connector to your harness at the end for a clean install.

For the most part this in incorrect. I think you're confused about EV1 vs. EV6 vs. EV14 connectors. Most everything from Ford starting in 2005 uses a EV6 / EV14 connector.

[DPDISXR4Ti]

What is the output on our stock injectors? Once I know that I'll find a comparable output EV14 injector.

Answering my own question, this site provides the answer... https://www.injectorplanet.com/produ...sch-0280156065

In short, Bosch p/n 0280156065 or 06B133551M
Output:
25.1 pph
264 cc/min

Here's a couple options for EV14 injectors that are nearly the same output.

2000 - 2008 Jaguar S-Type 3L V6
2002 - 2006 Jaguar X-Type 3L V6
2000 - 2003 Lincoln LS 3L V6
2006 - 2009 Saab 9-3 2L
0280155863 / XW4E-A5C
24.7 pph
260 cc/min

2004 Ford Explorer (Mercury Mountaineer) Flex fuel 4L SOHC
0280156184 / 4L2E-E1A
25.5 pph
268 cc/min

[b6a41.8tbagg]

Looking good seerlah

[Fast4esT]

I just replaced my injector harness as mine was also pretty brittle and hading breaking and exposed wires. I was under the assumption that since all the ground wires are the same red with blue stripe that it does not matter which ground wire goes to which injector. Car has a much worse misfire now and flashing CEL. Are the ground wires specific to a certain injector number? If they are specific how do I figure out which one is which? Why would they all be the same color if they where specific to certain number injector.
I used butt connectors, perhaps there is resistance in my connections?

thanks, Im stuck

[b6a41.8tbagg]

You should have labeled them 1-11, 11 being the furthest injector wire to keep track of them. Heres a couple schematics if that helps. IMG_7726.jpgIMG_7727.jpg


Sent from my iPhone using Audizine

[DPDISXR4Ti]

Some data I gathered over the past month. Note, much of it came from eBay fuel injector cleaner/seller "neinjectors603" who was very forthcoming with his test-data even though in the end, I didn't give him any business. But he really seemed like a knowledgeable and stand-up guy, so I felt he deserved a plug.

Any way, the 12-hole green injectors from a Jaguar X-type (p/n 0280155863 / XW4E-A5C) test out at between 238 and 246cc. Our stock blue ...065 4-hole injectors test out at about 250cc, so only a tiny bit more. I'm sure they would work, but I'd certainly feel better about going over rather than under. Given that, the white injectors from the Ford 4L SOHC engine are probably a safer bet, it just would be interesting to see if the 12-hole injectors do any "magic".

Is there an adjustable FPR for our engine?