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 Post subject: Re: Injector replacement?
PostPosted: Thu Dec 08, 2016 10:45 am 
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Parts arrived yesterday so I braved the wind and cold last night and got her fixed up. Back to purring like a kitten.

The picture below shows the kit contents (table cloth not included). The wires are both 18 GA solid blue so I'm not sure at the moment what differentiates a kit for each injector. Contacts and seals are already applied to the wires so no crimping tool required.
Image

Here is my pigtail wire. One wire is marked with pieces of tape to tell which is which. The original was also twisted, likely to prevent electromagnetic interference so I did the same. I also don't care for the connectors that were included so I used my own.
Image

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 Post subject: Re: Injector replacement?
PostPosted: Thu May 11, 2017 12:50 pm 
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This issue seems to have come back after 6 months and I'm confident the injector is not the cause. I can produce an injector miss (or what seems to be it anyway) by flexing the engine harness at the ECU connector. I'll get it scanned to be sure though.

I did get the engine to stall once and would only crank. After playing the engine harness again I did get it to start.

Has anyone had issues like this before with the engine harness?

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Thu May 11, 2017 2:07 pm 
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Sounds like either a broken wire or a frayed wire. 2006? Check the harness as it passes behind the fuel head, that bracket is a known problem spot where it rubs through the shield and shorts.

Otherwise, I think you have to just unwrap the area you are flexing and start digging around for any broken wires. Good luck - electrical troubleshooting is a nightmare.


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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Thu May 11, 2017 3:18 pm 
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Make sure the ecm connector is clean and making good contact. Make sure none of the pins appear to be push back slightly or are loose. If they are not fully seated, the vibration can cause intermittent problems like you are experiencing.

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Thu May 11, 2017 4:30 pm 
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It's a 2005. I did look at it a bit last night and noticed the one of the injector wires for #1 seems to have a sharp bend to it right before it goes into the ECU connector. Possibly broke inside the insulation?

I had the entire harness (behind the fuel filter too) apart one day last fall looking for anything broken. I'll have to check it out again.

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Thu May 11, 2017 5:17 pm 
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well then you have misalignment pin so can you get small pick and straighten it


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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Thu May 11, 2017 7:40 pm 
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Stopped and got it scanned before I went home and confirmed the issue is on the #1 injector circuit.

The ECU pins seem to look OK. Nothing bent or burnt. Pins needed are 25 and 74. I stuck my phone in there and got a picture. If it's nice out this weekend I'll pull the ECU out and look in there.Image

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Fri May 12, 2017 5:59 pm 
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I pulled the ECU after getting home from work and can see that some of the pins are a bit dirty, including those for the injector circuit. You can actually see that there is something on pin 25 in my picture from yesterday.

Is there a good way to clean them? Electrical contact cleaner and compressed air?

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Fri May 12, 2017 9:41 pm 
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I got some contact cleaner and cleaned up the pins. None were pushed in or loose. It's put back together now and still has the issue. With that I'm being lead back to believing something is up with that connector. Has anyone ever taken one apart?

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 Post subject: Re: Injector replacement?
PostPosted: Sat May 13, 2017 11:41 am 
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Based on what you posted a couple days ago, it sounds like there's an intermittent connection somewhere in the wiring harness at/near the PCM connector. I would connect a multimeter, set to continuity check, between the injector connector and its corresponding pin at the PCM connector and flex the wiring harness to determine where the intermittent connection/break is.


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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Sat Jun 17, 2017 10:15 pm 
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So I've been driving this around for about a week now and the engine hasn't missed a beat. What I ended up doing was replacing BOTH terminals in the "ECU 1" connector that correspond to the #1 injector.

Here is as much data as you would ever want for the connector, including drawing, associated part numbers, ect.https://www.bosch-connectors.com/view/product/154P-E-EMS-Contact-Housing-96P-Code-A-Exit-right/1928404927

Here are the terminals I bought. I got enough to do others if I had issues with other circuits. To change these you will need a Pacard type crimp tool.
http://store.chiefenterprises.com/Products/Bosch-Matrix-Terminals/1928498677-Matrix-Terminal-75-1-0-sq-mm-Silver

To get inside of here, pry the cover off the back at the bottom corners with a small screw driver. Fingernail works too.
Image

Slide the purple keeper past your cavity, or completely remove it.
Image

You'll need something small to put in the small hole to release the terminal. I used a small sewing needle. Once released you'll be able to pull the wire out. Reassembly is reversed.
Image

I did have trouble pushing one of the terminals back in far enough to lock. I figured out I was able to slip something flat and small in cavity with the wire to push the terminal in the rest of the way. I had a terminal release tool, but a small screwdriver may work. You'll need to push the side of the terminal opposite the small hole used to release. If you try anywhere else you may stab the insulation in the wire. Be careful doing this so you don't again stab the wire.

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Sun Jun 18, 2017 12:43 am 
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Thanks for the pics and information.
I hope this is a permanent fix for you!

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Sun Jun 18, 2017 9:43 am 
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Glad to share. Hopefully it helps someone else with this issue or something similar.

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Sun Jun 18, 2017 1:05 pm 
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Nice work!

Want to come troubleshoot a wiring issue on my VW? :SOMBRERO:

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Tue Jun 20, 2017 11:44 am 
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geordi wrote:
Nice work!

Want to come troubleshoot a wiring issue on my VW? :SOMBRERO:


Yes. Nice job! Injectors are $1000 ea. at the dealership for these rigs so your time was well spent! I also noticed you don't have your location on your profile. Probably best as now there will be a bunch of us trying to buddy up to you for electrical work...

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 Post subject: Re: Injector replacement? - Update - Not injector
PostPosted: Tue Jun 20, 2017 1:55 pm 
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I'll help anywhere I can. I'll have to update location later, but I live in Wisconsin, an hour north of Wausau if anyone is familiar with the area.

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