I post this report in frustration at the amount of "ripping off " going on with regard to the perennial TD5 issue of diesel in the ECU. Hardly a week goes by that there is not a report of someone paying R15 000 or more to fix the problem. I wish to record some facts and ask all members to be aware and warn potential victims. Repairing this problem is no big deal - possibly equivalent to changing plug wires on a V8. Should be cheap and quick. The symptoms are jerking and missing while accelerating , caused by diesel entering the ECU via the plug (see Pic) There has not been a solution to the problem - even late model TD5's can suffer from it. It is caused by high pressure diesel being forced into the wires at an injector , and travelling between the copper wire and the insulation all the way down to the ECU . Fixing the problem consists of cleaning the ECU (flush out with a solvent and dry ) and replacing the injector harness. Note that this harness is a very simple item with 5 x2 plastic insulated wires , terminating in a plug at the front of the tappet cover. Should cost about R10 to produce - LR of course charge about R700 . Replacing this is simply a matter of removing the tappet cover , unplugging 5 injector feed plugs and one connector plug to the wiring loom at the front of the tappet cover and then fitting a new harness (same procedure in reverse), Bingo . Half hour labour (unskilled ) and the bill can be R15 000.Workshop survival in tough times ... For those who do not wish to pay LR R700 for an injector harness , there is an alternative free fix: As can be imagined , to force diesel down a meter or more of insulated wire takes a lot of pressure(remember the injectors generate 22 thousand PSI). All we have to do is make provision for the diesel to find an easier route out . This can be done by piercing each wire with a needle - so allowing the diesel an easier exit . Or cut and resolder each of the 10 wires , thus breaking the insulator route.Just ensure that the soldered joints are insulated again . The Pics are courtesy of Les Henson , as published in lr4x4.com.

Dave

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