R400 Duratec Coil Pack Wire Broken

[moorsd123]

Experienced some rough running recently so had a look this evening, turns out one of the wires to the coil pack on No1 cylinder must have been on its way out as it easily broke off when I disconnected the plug!! 

I've ordered a new plug to repair it but been reading that there is an upgraded coil pack loom available from Caterham? However looking on the picture it looks like there is a plug that connects to the main loom...trouble is doesn't look like the loom in my engine has this connector plug??

Does anyone have any experience with installing this upgraded loom? Is it a case of having to cut into the old loom to install a new connector so that the upgraded coil loom plugs in?

Many Thanks!

[John Vine]

That's exactly what happened to me (2008 R400D).  See this thread.

It's a well-known problem on early Duratecs, and caused by a combination of inadequate wiring and high-frequency engine vibration.  The permanent solution, as you say, is to fit CC's flexi-loom (3AL080A).

Is it a case of having to cut into the old loom to install a new connector so that the upgraded coil loom plugs in?

Yes, but it's not difficult, provided you are happy crimping Econoseal terminals.  Post #20 in the thread above explains what to do.

That earlier thread contained a link to photos on Photobucket.  Unfortunately, it gives a 404 as PB (in their attempt at money-grubbing) have now deactivated my account as they no longer offer free storage, and I have absolutely no intention of paying them to reactivate!  Luckily, I still have the photos.  Here's a selection:

CC's Workshop Notice WN515 explains the connections:

You'll need a 6-way male Econoseal:

Splice this into the existing loom:

The final connection:

  

The Econoseal 6-way connector, with flexi-loom female on the left, and the spliced-in male on the right:

   

Let me know if you need more info.

JV

 

 

 

[moorsd123]

Thanks John, you're a legend!

Think I'll do a temporary repair by fitting a new standard connector and buy the upgraded loom to fit as a "winter job".

Just one question...and it's probably me being dim, but there are 8 wires in the picture but only details of where 6 go in the connector...where do the remaining 2 go, or am I missing something?

 

[moorsd123]

...sorry should have read #20 on the original post first, as you've explained the doubling up of the ground wires there!

Thanks again!

[John Vine]

Glad to help.

 A short-term fix would be to solder a length of wire between the fractured #1 loom wire and the connector terminal. That's what I did (at a Llandow trackday), but IMO it would be better to fit the flexi-loom asap.

JV

[moorsd123]

Well, installed the upgraded loom this morning seems to be all working OK...actually think the car is more responsive, (could be psychological though).

Only fiddly bit was getting the econoseal connector together properly so the pins would allow the locking plate to fit in the connector!

Thanks for your input John, think I would have struggled without all the info you supplied!

[John Vine]

Excellent news, and thanks for the feedback.

Out of interest, what crimping tool did you use?  Mine was recommended by Polevolt (P/N TT320), but seems to be no longer available from them.  It was a GC/Waldom W-HT-1921:

JV

[moorsd123]

I bought the below crimping tool from Ebay. Glad I did as after trying a test crimp on my standard wire stripper/crimp tool it was pretty hit and miss. The dedicated crimping tool gives a much more consistent result!

[John Vine]

Thanks.  That's a very keen price -- cheaper than my Waldom!  And it appears to have a ratchet too.

[ETA:  Linky for anyone looking for that Econoseal crimping tool.]

JV