Fuel Rail Pressure sensor & Harness change

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zoolander

zoolander

New Member
Posts
375
Location
Chatham, Kent
(2005 TD4)
Following 2 major breakdowns this week - one in the middle of a very busy roundabout :eek: have come to the conclusion I have a failed fuel pressure sensor. This was brought to my attention by the second break down man (car break down not mine ;)) - he phoned a friend who works for the AA - apparently they have the contract for Land Rover break down now. The AA guy on the phone advised his friend to look for the fuel sensor on the end of the fuel rail and check for corrosion/greening. Now I have cleaned this myself in the past so knew already about it but decided to keep quiet. He struggled to get it out but once removed cleaned it and sprayed with WD40. Once plugged back in the car started - it wouldnt run before. Only thing is MIL was on as I limped home.
Once home I removed all the pipework to gain access and found he hadnt put the plug in properly. Once fitted MIL went out :D. Anyway I gave it a good clean out with contact cleaner and took for test drive. Fixed.
I was given some advice to try a silicon grease to keep the moisture out so next morning went to Maplins got a tube, unpluged the fuel sensor and gave the contacts a good covering. Following this drove the car on a 100 mile round trip mainly motorways it didnt miss a beat. That evening took driving to my local park the car started to run lumpy again, MIL came on and I limped to the park. Stopped the engine for 40 minutes restarted and the MIL went out - drove home no problems. This morning MIL back on and now wont go off :mad:
During my 4 months of ownership Ive had 3 different RAC patrols try to connect there laptops up and read any fault codes - all failed. Also had a mobile Auto Electrician try and said there was no fault codes when the MIL had been on previously!
Im seriously thinking of changing the following parts;
STC4768 Fuel sensor
YMQ503320 Harness
I phoned one Land Rover dealer in Kent who said he would reduce the total parts price of £240 to a trade price of £206. I did ask about the O ring but was told this comes with the sensor.
I also phoned another Land Rover dealer and asked for the price to fit these parts. He phone me back with a price of £420!
Anyway my main question is, is this a difficult job? There must be something big involved for the extra £214 to fit these parts?
 
zoolander said:
(2005 TD4)
Following 2 major breakdowns this week - one in the middle of a very busy roundabout :eek: have come to the conclusion I have a failed fuel pressure sensor. This was brought to my attention by the second break down man (car break down not mine ;)) - he phoned a friend who works for the AA - apparently they have the contract for Land Rover break down now. The AA guy on the phone advised his friend to look for the fuel sensor on the end of the fuel rail and check for corrosion/greening. Now I have cleaned this myself in the past so knew already about it but decided to keep quiet. He struggled to get it out but once removed cleaned it and sprayed with WD40. Once plugged back in the car started - it wouldnt run before. Only thing is MIL was on as I limped home.
Once home I removed all the pipework to gain access and found he hadnt put the plug in properly. Once fitted MIL went out :D. Anyway I gave it a good clean out with contact cleaner and took for test drive. Fixed.
I was given some advice to try a silicon grease to keep the moisture out so next morning went to Maplins got a tube, unpluged the fuel sensor and gave the contacts a good covering. Following this drove the car on a 100 mile round trip mainly motorways it didnt miss a beat. That evening took driving to my local park the car started to run lumpy again, MIL came on and I limped to the park. Stopped the engine for 40 minutes restarted and the MIL went out - drove home no problems. This morning MIL back on and now wont go off :mad:
During my 4 months of ownership Ive had 3 different RAC patrols try to connect there laptops up and read any fault codes - all failed. Also had a mobile Auto Electrician try and said there was no fault codes when the MIL had been on previously!
Im seriously thinking of changing the following parts;
STC4768 Fuel sensor
YMQ503320 Harness
I phoned one Land Rover dealer in Kent who said he would reduce the total parts price of £240 to a trade price of £206. I did ask about the O ring but was told this comes with the sensor.
I also phoned another Land Rover dealer and asked for the price to fit these parts. He phone me back with a price of £420!
Anyway my main question is, is this a difficult job? There must be something big involved for the extra £214 to fit these parts?
Click to expand...
Sounds very similar to my problems, except I've only had mine a month and I had the parts supplied and fitted under warranty.

PS my sig needs updating!
 
I haven't fitted the overlay harness kit, always preferring to clean up the existing wiring which I know you've tried, but from what I gather it consists of, it should be easy enough to do for anyone reasonably competent with vehicle electrics.
It comes as a new sensor plug and wiring that you have to route through a new hole in the E-Box and then on to the ECM plug. You remove the old wires/pins from the ECM plug and fit the new wires/pins in their place.

£214 labour for fitting a sensor and a few wires, I'd be happy to do them all day long!
 
I suffered from a misfire under load and cured it by just swapping the pressure sensor harness. thought i'd try that first, as harness and sensor were available individually. The original harness twists and turns all over the place so no surprise fault was caused by a broken wire.
 
Well Ive just changed the loom and all fixed - MIL off car running fine.
Got a good discount from a Land Rover dealer in Kent cost £32.34. The new loom is shorter than the original so has to go directly to the ECU box. Probably the proper way to install this would be to drill a hole in the side of ECU box and install thru there. I made a small cut in the top of one of the rubber shrouds carrying cables into the box and inserted the new cable there instead, wrapping the shroud in insulating tape.
The 3 new wires went into a plug at the front of the box. This is the third plug from the right - I removed the other two to enable access to the plug to be worked on.
The plug you need has one black block and one grey block. Each block is numbered with 4 rows of 13. The two blocks can be slid from the holder to enable fitting the new wires shich are a push fitting.
pin 20 is brown/green
pin 33 is blue/black
pin 35 is white/yellow

So the money Ive saved is going down the bookies for Man Utd to beat Barca 2 -1 :)
 
Don't know if it is of any help but the August 2009 edition of Car Mechanics detailed this job in an article on Freelander TD4 diagnostics. Back numbers used to be available.
 
I got a genuine Bosch fuel rail sensor from The Landrover Centre in Huddersfield for £80 +vat. They do mail order too.
 
anyone please have a pdf of the updated sensor harness fitting instructions? What's the big foam circle for? Would be a help, thanks
 
I didnt use the foam circle when I fitted mine, so sorry cant help.

If I get time Saturday I will photograph how I ran the cable. All fairly easy.
 
Thanks that would be great - to be honest the big foam wheel is the only part i couldn't figure out....plus the small bit of plastict that looks like a connector guard of some sort.
 
cheers, don't have TSB to hand, can't find it on the net, Land Rover in the Czech Republic refuse to give it to me and / or deny it exists depending on who i ask :)
 
I know this thread is getting on now, but just wanted to say that thanks to this site in general, and this thread in particular, I've managed to sort out my 2004 TD4. After weeks of problems which resulted in me almost building a bonfire out of it, renewing air filter, cleaning the EGR and PCV, it is now sorted. Problem turned out to be a dodgy fuel rail sensor harness plug. Fitted a new one today, and would just like to thank Zoolander for the info on where the cables go at the ECU. Wouldn't have been able to do it without that information. So....THANK YOU. You've saved me a fortune by not buying a MAF or a fuel rail sensor.
 
Dave , if could give me pictures that would be great id appreciate it, tells a thousand, words discription is good im just one of thos people that need to see something.
 
Well ive taken a picture and marked in red the cable coming from the sensor/plug. I cut the rubber grommet on the side of the box to route the new cable thru then sealed with tape.
The badly drawn arrow points to the area where you wire the loom in.
If you follow the previous instructions you should have no problems. Its a fairly easy job.
Any questions please feel free to ask.
regards
Dave
 

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Got it , found the break when i was changing cam sensor noticed wiring at the filter passager side with blue wire connectors touched the connectors and cable fell out of crimp re crimped light out problem sorted so well happy. took copy of pic for future ref
 
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