How difficult to change injector seals in TD5?

[Hamish71]

As per the question, have noticed that the oil level in my D2a has increased since last service. No water/coolant visible. Assuming its leaky injector(s). How dificult are these to change?

[Psimpson7]

Its pretty easy really.

These are them:

https://www.aulro.com/afvb/images/imported/2011/03/997.jpg

Remove rocker cover
unplug injector loom
Unbolt saddle clamp holding down injector

https://www.aulro.com/afvb/images/imported/2011/03/998.jpg

Using a small "L"shaped lever of some sort, prise out injector (I used a long allen Key)

https://www.aulro.com/afvb/images/imported/2011/03/999.jpg

Remove seals from Injectors (o'ring and copper washer) - be careful removing the copper washer that you dont damage the sealing face on the injector.

https://www.aulro.com/afvb/images/imported/2011/03/1000.jpg

https://www.aulro.com/afvb/images/imported/2011/03/1001.jpg

Fit new seals

https://www.aulro.com/afvb/images/imported/2011/03/1002.jpg

refit

https://www.aulro.com/afvb/images/imported/2011/03/1003.jpg

repeat for 5
refit loom
refit rocker cover

[Hamish71]

Now THAT, is an answer!

Part No.s, Process, Pictures......it doesnt get any better than that.

Is it worth getting the injectors "cleaned" and/or tested whilst they are out?

Mods, please put this straight into the good oil! Suggest you change the thread title to "How to Change TD5 Injector seals".

[999]

Thanks mate,:thumbsup: this helped me a great deal especially using an allan key as a lever.

[CraigE]

Question: Can you clean these injectors in an ultrasonic bath like most injectors?
Thanks

[strangy]

A quick note that the pics here are with the camshaft removed and that with the camshaft still in place (ie head not coming off) I have found the injectors are a little bit more fiddly to lift out as the camshaft can get in the way. Just requires a little more patience and care.

cheers

[robbotd5]

As per the question, have noticed that the oil level in my D2a has increased since last service. No water/coolant visible. Assuming its leaky injector(s). How dificult are these to change?
All good presuming your head is not cracked:wasntme:Hopefully the seal/o ring change will fix the problem.;)
Regards
Robbo

[Giles]

TD5 2003 260K

can I remove the injectors without removing the camshaft?

I am replacing the copper washers and orings.
More importantly, can I refit them without having to slacken anything off, I really dont want touch anything I dont have to.

Regards,

Giles

[Giles]

Maybe I just meant the rocker shaft

:o

[Disco W.A]

Giles,
Have a look on www.discovery2.co.uk (http://www.discovery2.co.uk)

In the workshop section there is a procedure that covers this task, it's well worth reading.

[sandu]

Hello guys,
I did the injector seals/washers change twice on my D2 and Defender.
when I proceeded, I was suggested by some mechanics to warm the washers until they got red, and then submerge in water. This way the copper becomes softer and gives better sealing.

I wonder if anyone of you did this? What do you think about? How long do you usually drive you car until you need another seal/washer change?

[rick130]

Hello guys,
I did the injector seals/washers change twice on my D2 and Defender.
when I proceeded, I was suggested by some mechanics to warm the washers until they got red, and then submerge in water. This way the copper becomes softer and gives better sealing.

I wonder if anyone of you did this? What do you think about? How long do you usually drive you car until you need another seal/washer change?It's called annealing, and the washers should be annealed out of the packet.

You'd only anneal them if you were going to reuse used ones (copper work and age hardens)

[PhilipA]

I would add to that to clean the tip of the injector of carbon.
There is actually a ridge on the injector tip which helps seal the copper washer which is pretty hard to see through the carbon.
I used a dental pick to clean the carbon off the injector surface, CAREFULLY.
I am talking about the flat surface that the washer mates to.
Also check that the surface of the head where the washer sits is very clean.
To seat the Orings , make sure they have some diesel on them, push them down as far as they will easily go, then tap the injector with a hammer handle end to fully seat them.
Regards Philip A
Of course you then have to reset the injector clearances once you have the rocker shaft back in.