Hi Guys;

Misfire code; replaced the plug, didn't fix it. Checked spark, was very weak. Decided to replace coils, wires, plugs.

Pulled intake, removed old coils and brackets. I manufacture electronics, so sourced the standard 3 pin Bosch Plugs, Receptacles, and Terminals myself and made some extensions. The parts (which took me quite some time to find and verify would fit) are listed here for posterity's sake in case anyone else wants to do this:

828748-3 (Female 3 Pin Bosch Compatible Receptacle)
1-962581-2 (Male 3 Pin Bosch Compatible Plug)
964284-1 (Female Terminal Sockets, many other part numbers available for this, but these work well)
1-962841-2 (Male Terminal Pins)

If you plug these part numbers into www.mouser.com you can order. You need 2 each of the plugs/receptacles, and 6 each of the sockets and pins, but splurge and get some extras in case you mess up the crimping)

I crimped these using the tool I had on hand, but a "real" crimper will obviously help. After crimping, I flooded the crimp and exposed wire with solder (see pic) then installed the wires and used a few layers of large heat shrink tubing around the connectors to act as a strain relief. A bit of coil wrap on top of the loose wires also helps keep it tidy.



Now, I am looking for the appropriate, longer length spark plug wires to finish the job, I have reached out to Magnecor, but hoping somebody here might be able to add to this thread (again, for anyone else doing this job in the future) with an appropriate ordering number.

Thank you!

 

You've pinpointed why I do *not* do the relocation. I found it nearly impossible to source the correct length wires for the relocation kits.

 

You might call Kingsborne as they supplied the longer wires that I used with the relocation kit that I installed to see if they have what you need.

 

The pic in the OP's post is not showing up.

 

If you need the Kingsborne wires, please contact Kris directly at 760-736-4020 and ask for the LR relocation kit., gerry has this set up already with them so when you call they know exactly what your talking about

 

Yes, as RedWhiteKat mentioned…call Kingsborne. Ask them to supply you with the standard part number for their 8mm wires for the Discovery. Or you can look it up on the Kingsborne ordering site.

Then ask them to add a “GC” suffix to the standard part number. The “GC” stands for “Gerry Conder” who arranged with Kingsborne to supply some longer length plugs wires for the relocation kit.

 

Additional info now that I am home and can check my notes....

The new location of the coils is on the passenger side. This means the spark plug wires going from the new coil location (passenger side) to the driver side will need to be relatively longer than the original factory wires.

Kingborne has the best deal for spark plug wires. Make sure to use part # IGN 790GC. Be sure to include the "GC" suffix at the end. The "GC" stands for Gerry Conder who is the name of the original creator of this relocation kit. Gerry contacted Kingborne. He asked Kingborne to take their standard "IGN 790" set and customize it to his specs. The modified part number is IGN 790GC.

 

And I bought 2 spark plug connector covers in natural (colored ones are too tight, I know...) to cover the wires that go across the alternator. I wanted some more insulation between the plug wires and the alternator.

 

For some reason I was not getting updates on this thread, and I went ahead and made 4 plug wires to reach from the relocated coils to the drivers side (LEFT) spark plugs.

So, there is now more to the story. Two of the plugs were "JC" tight (Jesus Christ) when I went to remove them. Of course plugs 7 and 8. Whoever was working on this truck prior to my ownership was not great. I found a 10mm wrench nestled behind the engine where the old coil packs were!

So the 7 and 8 spark plug holes in the block were a little chewed up, hence probably why the plugs were JC tight. I chased plug 8, cleaned it, and installed the plug with no incident. Did the same for plug 7, however that plug is getting compression leak by. I cleaned the threads again (after removing the SAI pipes on that side to get better access) and tried facing the plug hole to smooth it out. It is better, but still getting a leak.

I am getting fairly frustrated with the truck at this point because I still have the cyl 2 misfire showing up after doing this entire project and now of course a cylinder 7 misfire. That plus all the other codes, I'm starting to lose faith.

Someone please give me a good dose of motivation to get this thing fixed!

FWIW, the coil relocation and extended wires all worked fine; so my "new" work was tight, its just this engine/truck seems to have had poor work/maintenance in the past. 109k miles, and very clean inside, so its a shame that its not driving now. I even got the AC working and did the thermostat fix!

 

Don't lose the faith! These are old Land Rovers and they seem to be a sea of "issues". For some reason, we still love them! You are making good progress so keep it going and realize that you may never "fix" it but should have fewer problems over time. Stay at it if you can.