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Unread 03-31-2014, 08:34 PM   #1
LonnieD
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1991 YJ Wrangler 
 
Join Date: Nov 2011
Location: Sevierville, TN
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Fuel Injector Connector Pigtail

The plastic wiring case next the fuel rail is broken, and the electrical tape inside is brittle, flaking off. I gathered connector pigtails figuring I could add fresh connectors while everything is pulled out. My plan was to solder the pigtails onto the harness wires, but now I wonder if I should re-tape and leave the connector wires alone. I found one thread about soldering, but need advice on go/no-go the replacement. Thanks!

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Unread 03-31-2014, 09:11 PM   #2
imstillatwork
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1993 YJ Wrangler 
 
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Location: Oregon Coast, Oregon
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I like to use the inline twist and solder methods.
Sometimes I use a crimp butt connector without the plastic, then solder.
Either way finish with heat shrink tubing with plenty of overlap to seal it up.
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Unread 03-31-2014, 09:12 PM   #3
imstillatwork
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This is actually a good writeup if you are a total wiring noob.
http://www.instructables.com/id/Mast...time/?ALLSTEPS
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Unread 03-31-2014, 09:16 PM   #4
imstillatwork
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Third post, just to clarify there are two parts to a wiring connection
ELECTRICAL and MECHANICAL
Make sure you get both. Solder is an electrical connection and should never be treated as a mechanical one!
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Unread 04-01-2014, 07:29 AM   #5
Que89YJ
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1989 YJ Wrangler 
 
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Plastic wiring case? Is it the loom that goes around all the wires or the wire coating itself?
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Unread 04-01-2014, 12:00 PM   #6
imstillatwork
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1993 YJ Wrangler 
 
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Quote:
Originally Posted by Que89YJ View Post
Plastic wiring case? Is it the loom that goes around all the wires or the wire coating itself?
Good catch! I ASSumed he was describing the connector end and being cracked, which they can/do after 20 years of heat cycles.
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Unread 04-01-2014, 12:23 PM   #7
Que89YJ
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1989 YJ Wrangler 
 
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You do not need to replace the injector wires. They are not a wear part and should last the lifetime. The wire loom cover and tape is an easy replacement but in no way would I replace a connector or wiring that did not need it!
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Unread 04-01-2014, 03:26 PM   #8
imstillatwork
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1993 YJ Wrangler 
 
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Quote:
Originally Posted by Que89YJ View Post
You do not need to replace the injector wires. They are not a wear part and should last the lifetime. The wire loom cover and tape is an easy replacement but in no way would I replace a connector or wiring that did not need it!
Agreed. I have HAD to replace several on other cars, and I mis-understood the OP's issue this time.

There really isn't much worse on a used car than finding out the previous owner hacked up the wiring
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Unread 04-01-2014, 06:45 PM   #9
LonnieD
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Location: Sevierville, TN
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Well, then the EFI Wire Cover, which encases and protects the injector and forward mounted sensors, is broken and the 300K miles have taken their toll on the injector wires that protrude from that plastic thingie. (Quadratec has a nifty billet EFI cover thingie for $89.99). I'm the only PO "Sun" (Islander) has/will have so I am hacking 'em. We fumbled through long block, head rebuild @250K, so now the old boy going to get beucoup connector/wire replacement. The boots on the injector connectors are all shot - probably too much heat from the header upgrade. Sandblast, paint, wrap should fix that in the future. Anyway, thanks guys. 'Appreciate the help.
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Unread 04-01-2014, 08:36 PM   #10
Que89YJ
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Pic helps. Can't see doing it if you make a problem for yourself later. Pig tail it's ok. shrink wrap any connection under the hood.
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Unread 04-01-2014, 10:13 PM   #11
LonnieD
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Check
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Unread 04-02-2014, 10:56 PM   #12
LonnieD
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Location: Sevierville, TN
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Noob Splice

OK. Here's the hacked injector connector splice. Western Union wrap (1"), solder, double heat shrink (1.5" on splice, 2" on 1st shrink tubing). Resistance same as unspliced wire. New connector boots due tomorrow and I can get through, then get the whole fuel tank problem resolved.
splice.jpg

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