Fuel Rail Connector. Having driven from the South of Spain...to the Isle of Skye via Amsterdam – for the ferry to Newcastle, the one and only problem I had with my Freelander 1, Td4, HSE 2006, 2.0 diesel was the Fuel Rail Connector breaking its connection. I used my IcarSoft Diagnostics scanner to determine where the problem lay, and it was correct. I wouldn't travel far without one of these marvelous units.

Having cleaned the plug’s connections, the car drove okay - for a while, until the fault happened again. After another clean, followed by a spray of WD40, it lasted for a very long time until it eventually played-up... again. That persuaded me to do something more permanent. And rather than buy another connector that might very well prove to be problematic, I went for something else.

I fabricated a cable; one that connected to the existing car’s wiring harness using an in-line plug and female spade crimps.
I bought the following items on Ebay for this project…

Blue Insulated Female Spade Terminals Crimps Electrical Wire Connectors 15A
Size 0.8mm x 2.8mm


IP68 3/4/5/6 Pins Assembled Waterproof Electrical Cable Connector Plug Socket YX


Then it was a case of cutting the existing plug off the harness and replacing it with my own.

All the joints are soldered and the in-line plug/socket has been given an extra seal using clear mastic over the soldered joints.

While soldering the car’s harness wires to the in-line connector I disconnected the ECU in its entirety. I didn’t want any possible charge (back EMF) from the soldering iron to reach its electronics.

Then it was simple case of connecting everything and ensuring it was all protected and safe.

The old plug? I’ve used it to make another cable, one that can be connected to the in-line connector. Just in case.


The cost of all this is less than €10 and I hope the fault does not rear its head again.

PopRivet said:

Fuel Rail Connector. Having driven from the South of Spain...to the Isle of Skye via Amsterdam – for the ferry to Newcastle, the one and only problem I had with my Freelander 1, Td4, HSE 2006, 2.0 diesel was the Fuel Rail Connector breaking its connection. I used my IcarSoft Diagnostics scanner to determine where the problem lay, and it was correct. I wouldn't travel far without one of these marvelous units.
View attachment 161037
Having cleaned the plug’s connections, the car drove okay - for a while, until the fault happened again. After another clean, followed by a spray of WD40, it lasted for a very long time until it eventually played-up... again. That persuaded me to do something more permanent. And rather than buy another connector that might very well prove to be problematic, I went for something else.

I fabricated a cable; one that connected to the existing car’s wiring harness using an in-line plug and female spade crimps.
I bought the following items on Ebay for this project…
View attachment 161038
Blue Insulated Female Spade Terminals Crimps Electrical Wire Connectors 15A
Size 0.8mm x 2.8mm

View attachment 161039
IP68 3/4/5/6 Pins Assembled Waterproof Electrical Cable Connector Plug Socket YX
View attachment 161042

Then it was a case of cutting the existing plug off the harness and replacing it with my own.
View attachment 161041 View attachment 161043 View attachment 161044
All the joints are soldered and the in-line plug/socket has been given an extra seal using clear mastic over the soldered joints.

While soldering the car’s harness wires to the in-line connector I disconnected the ECU in its entirety. I didn’t want any possible charge (back EMF) from the soldering iron to reach its electronics.

Then it was simple case of connecting everything and ensuring it was all protected and safe.

The old plug? I’ve used it to make another cable, one that can be connected to the in-line connector. Just in case.
View attachment 161045

The cost of all this is less than €10 and I hope the fault does not rear its head again.

Click to expand...

That's a lot cheaper than the "official" uprated harness.

Did you renew the connector and terminals to the actual fuel rail sensor? Or just used spade terminals onto the sensor connections?

I had the same problem. You may not like this. I unplugged the high pressure fuel rail sensor and noticed that although the plug is designed and supposed to be a moisture tight seal, it was a little damp. I cleaned it and made sure it was very dry because the problem was the ingress of moisture such as condensation. I smeared a little silicon grease, like a very small amount, around the plug then plugged it back in. The plug is sealed and the problem has gone. This was 2 years ago.
But I think your wiring and soldering is great. Very neat. And only £10. I don’t know what the silicon grease cost. I think someone gave it to me.

td4van said:

Did you renew the connector and terminals to the actual fuel rail sensor? Or just used spade terminals onto the sensor connections?

Click to expand...

Hi. Yes, I used the spade terminals and they are a perfect fit. Nice & tight. The beauty of what I have done is that I can revert back to using the original plug, should I need to.
I was out in the car today and it ran perfectly. The replacement cable, with the original plug, is carried in my tool box and if I do need to fit it I can do it in seconds.

td4van said:

Did you renew the connector and terminals to the actual fuel rail sensor? Or just used spade terminals onto the sensor connections?

Click to expand...

Hi. Yes, I used the spade terminals and they are a perfect fit. Nice & tight. The beauty of what I have done is that I can revert back to using the original plug, should I need to.
I was out in the car today and it ran perfectly. The replacement cable, with the original plug, is carried in my tool box and if I do need to fit it I can do it in seconds.

I used one of these to replace a connector that was getting condensation inside:
https://www.ebay.co.uk/itm/3-Way-Bo...h=item1c63ae5c61:g:PS4AAOSw2ENW78ai:rk:1:pf:0
The pins and the seals work perfectly, I had to do a little whittling on the plastic guide slots to get it to engage correctly but no problems since changing the connector and about 10cm of the cable. The original connector is a Bosch part and you may be able to find a perfectly fitting replacement but at this price I am happy with a slightly hand-carved alternative.

blodge said:

I used one of these to replace a connector that was getting condensation inside:
https://www.ebay.co.uk/itm/3-Way-Bo...h=item1c63ae5c61:g:PS4AAOSw2ENW78ai:rk:1:pf:0
The pins and the seals work perfectly, I had to do a little whittling on the plastic guide slots to get it to engage correctly but no problems since changing the connector and about 10cm of the cable. The original connector is a Bosch part and you may be able to find a perfectly fitting replacement but at this price I am happy with a slightly hand-carved alternative.

Click to expand...

I must thank you for this information, Blodge. And would certainly order one... except, the buying price (for me in Spain) is: £5.89 + £15.99 P&P
This is one of the reasons why I rely upon my own ingenuity and cost-effectiveness. The Spanish have no real idea when it comes to inventiveness and common-sense. But don't quote me!
The Land Rover agents in Spain don't even bother to answer my emails when I ask about spares, etc, so I'm left to my own devices when it comes to fixing problems.
I rely on the UK & Ebay & LandyZone. Is it any wonder the Aramada sank? And thank goodness it did. lol Jeez, we'd all be driving a Seat!
I used what I had and did what I needed to. And I'm happy with the results.
I will, however, order what you have shown and have it sent to a family UK address. I'm heading to the Isle of Skye next May for another holiday; hence my need to have a fully serviceable and reliable Freelander.

blodge said:

I used one of these to replace a connector that was getting condensation inside:
https://www.ebay.co.uk/itm/3-Way-Bo...h=item1c63ae5c61:g:PS4AAOSw2ENW78ai:rk:1:pf:0
The pins and the seals work perfectly, I had to do a little whittling on the plastic guide slots to get it to engage correctly but no problems since changing the connector and about 10cm of the cable. The original connector is a Bosch part and you may be able to find a perfectly fitting replacement but at this price I am happy with a slightly hand-carved alternative.

Click to expand...

I must thank you for this information, Blodge. And would certainly order one... except, the buying price (for me in Spain) is: £5.89 + £15.99 P&P
This is one of the reasons why I rely upon my own ingenuity and cost-effectiveness. The Spanish have no real idea when it comes to inventiveness and common-sense. But don't quote me!
The Land Rover agents in Spain don't even bother to answer my emails when I ask about spares, etc, so I'm left to my own devices when it comes to fixing problems.
I rely on the UK & Ebay & LandyZone. Is it any wonder the Aramada sank? And thank goodness it did. lol Jeez, we'd all be driving a Seat!
I used what I had and did what I needed to. And I'm happy with the results.
I will, however, order what you have shown and have it sent to a family UK address. I'm heading to the Isle of Skye next May for another holiday; hence my need to have a fully serviceable and reliable Freelander.
OMG... I've just found the same plug with a much cheaper P&P.
https://www.ebay.co.uk/itm/3-Way-Bo...m=141644551067&_trksid=p2047675.c100008.m2219

I'm buying one.
Thanks Blodge. You are a STAR!

blodge said:

I used one of these to replace a connector that was getting condensation inside:
https://www.ebay.co.uk/itm/3-Way-Bo...h=item1c63ae5c61:g:PS4AAOSw2ENW78ai:rk:1:pf:0
The pins and the seals work perfectly, I had to do a little whittling on the plastic guide slots to get it to engage correctly but no problems since changing the connector and about 10cm of the cable. The original connector is a Bosch part and you may be able to find a perfectly fitting replacement but at this price I am happy with a slightly hand-carved alternative.

Click to expand...

I must thank you for this information, Blodge. And would certainly order one... except, the buying price (for me in Spain) is: £5.89 + £15.99 P&P
This is one of the reasons why I rely upon my own ingenuity and cost-effectiveness. The Spanish have no real idea when it comes to inventiveness and common-sense. But don't quote me!
The Land Rover agents in Spain don't even bother to answer my emails when I ask about spares, etc, so I'm left to my own devices when it comes to fixing problems.
I rely on the UK & Ebay & LandyZone. Is it any wonder the Aramada sank? And thank goodness it did. lol Jeez, we'd all be driving a Seat!
I used what I had and did what I needed to. And I'm happy with the results.
I will, however, order what you have shown and have it sent to a family UK address. I'm heading to the Isle of Skye next May for another holiday; hence my need to have a fully serviceable and reliable Freelander.
OMG... I've just found the same plug with a much cheaper P&P.
https://www.ebay.co.uk/itm/3-Way-Bo...m=141644551067&_trksid=p2047675.c100008.m2219

I'm buying one.
Thanks Blodge. You are a STAR!
I've bought it.

blodge said:

I used one of these to replace a connector that was getting condensation inside:
https://www.ebay.co.uk/itm/3-Way-Bo...h=item1c63ae5c61:g:PS4AAOSw2ENW78ai:rk:1:pf:0
The pins and the seals work perfectly, I had to do a little whittling on the plastic guide slots to get it to engage correctly but no problems since changing the connector and about 10cm of the cable. The original connector is a Bosch part and you may be able to find a perfectly fitting replacement but at this price I am happy with a slightly hand-carved alternative.

Click to expand...

I must thank you for this information, Blodge. And would certainly order one... except, the buying price (for me in Spain) is: £5.89 + £15.99 P&P

I will, however, order what you have shown and have it sent to a family UK address. I'm heading to the Isle of Skye next May for another holiday; hence my need to have a fully serviceable and reliable Freelander.
OMG... I've just found the same plug with a much cheaper P&P.
https://www.ebay.co.uk/itm/3-Way-Bosch-Common-Rail-Diesel-Injector-Plug-Connector-Kit-1928403966/141644551067?_trkparms=aid=333200&algo=COMP.MBE&ao=1&asc=54677&meid=e71cb0e161ac401cb3cb39e1c83d604c&pid=100008&rk=2&rkt=3&sd=121931455585&itm=141644551067&_trksid=p2047675.c100008.m2219

Thanks Blodge. You are a STAR!
I've bought it.

Oh no! LandyZone seems to be printing lots of my one reply. Sorry everyone. I'm not sure what's happening.

Oh no! LandyZone seems to be printing lots of my one reply. Sorry everyone. I'm not sure what's happening. Oooooerrrr.

PopRivet said:

Oh no! LandyZone seems to be printing lots of my one reply. Sorry everyone. I'm not sure what's happening.

Click to expand...

You are not the only one having this problem today - duplicate posts popping up all over the place.
Not the only one with postage issues either, I was quoted £2.99 for a set of four injector washers plus £15.99 postage because I live in the Scottish Highlands! I got a bit grumpy about that and found another supplier.