Harness corrosion, pass side footwell. How do I repair?
 

I have been having issues with my interior (dome) light not working. Today I cut the covering on the harness in the pass foot well. Wow did I find a mess. The three connectors C0289 (green) , C0286 (Gray), C0287 (Blue)) were corroded and wet. I am surprised I don't have more issues.

http://www.flickr.com/photos/40952238@N04/8542377625/

I started looking at and cleaning off C0287 because the dome lights go through it. One wire was already corroded loose, another fell off when I moved it and another came out of the connector with its connector. You can see the three loose wires (two are purple, purple w/ white stripe)

http://www.flickr.com/photos/40952238@N04/8542377511/
Here is what the front of the connector looks like.
http://www.flickr.com/photos/40952238@N04/8542377569/
I need to figure out where the wires came from.

Looking at the rave for the connector. I was planning on cutting wires 1-6 back until I got clean copper then putting spade connectors on them. The to a terminal block.

Do the same for 7-10 and 11-14 & 15-20.

Is this the correct approach?

Where should I be looking for the source of the leak?

That's quite the mess. Good find. Possible sources of water intrusion would be a/c drain tube, sunroof drain tube, or wind screen seal.

If still trying to figure out where they go you can have the circuts manual open and search for C0287 and it find each spot for it. If yo can figure out which pin number from the picture/connector layout in electrical manual you can search the circuits guide of C0287-xy and find that as well.

Prior to this my done lights worked intermittently and when they did work they did't come on when the drivers door was opened. I cleaned up and repaired the three connectors. My dome lights now work and they work when the drivers door is open. The headlight on chime now works.

Now I need to find the source of the leak. The AC drains don't have the nipples on them. I pulled the A-piliar trim because I have to change the wiper motor (it wasn't parking). I notices some small cracks in the sealant by the top of the pillar/rain gutter. I put black RTV over them.

I ordered pigtailed connectors from Paul Grant. I may just put the splice caps I get form Paul on the existing connectors, but I still have the option to replace the connectors long term. Most of the corrosion was in the caps. In the 2nd & 3rd photo from the 1st post, the brass pieces sticking out of the connector is supposed to be in the cap.

I also found out the the connectors Sumitomo HM/splice connectors (http://swsct.sws.co.jp/components/series/pdf/hm.pdf). They are discontinued, so I couldn't order new ones if I wanted to.

http://swsct.sws.co.jp/components/series/pdf/hm.pdf

Kudos to Paul Grant. I ordered 3 connectors w/ pigtails from him. The package showed up today and when I opened it, not only were they in perfect condition, there were a few extra.

thats the type of guy he is, he will usually ship me the fastener that he removed with the item, no one else does that.

Resurrecting the dead!
 

Hi I am having the exact same issue on my 01 disco. My headers are shot. I've looked everywhere to buy new but keep coming up with nothing. I've been told I could just wire all the same color wires together but want to do it the right way the first time. Any suggestions would be more than welcome

Oh wow. Note to self – fix the windshield leak ASAP!

You could contact Paul Grant for some used headers, or me for new ones :)

It's important that you replace them with the header of the same colour, as they are sub-divided differently -



BLACK
Attachment 34524

Sub-divided into five circuits -

Attachment 34525




BLUE
Attachment 34526

Sub-divided into four circuits -

Attachment 34527




GREEN
Attachment 34528

Sub-divided into four circuits -

Attachment 34529




GREY
Attachment 34530

Sub-divided into three circuits -

Attachment 34531




ORANGE
Attachment 34532

Sub-divided into six circuits -

Attachment 34533




YELLOW
Attachment 34534

Sub-divided into five circuits -

Attachment 34535



Supplied (as pictured above) with a 20-Way Splice Connector, Splice Cap and 20 x Sumitomo 090 Terminals.

They are £12.95 each + Postage from UK

Except for Grey and Blue, which are £19.95 each

.