TDV6 injector leak off pipe O-ring replacement

[gromit]

I have a problem with a fuel leak on a diesel Territory, it's from one of the injector leak off connections. Diesel leaks down onto the manifold causing a lot of smoke !!

Crazy money for a set of leak off pipes/connections so I'm hoping it's just an O-ring failed.

Has anyone had to do this on a Discovery and could maybe tell me the O-ring size. Looks like a fun job removing the cable tray to hopefully get to the injector !
Lets hope it's just an O-ring problem.



Colin

[loanrangie]

Not a difficult job really just need to be careful of the clips, I would just get an oring kit and match them.

[AK83]

I used Diesel Systems in Cheltenham (https://www.dieselsystemsaustralia.com.au/) to redo the fragile plastic leak off connectors on the Pug Hdi a while back. While they didn't specifically list the parts for the Puegeot, Ford parts are same, and in effect mine were just Bosch type fittings(as opposed to Seimens in some instances).

Took some samples and they matched them up. Helpful people.

I can't remember the prices of each bit and piece, got brass fittings and seals(plus a couple of spare seals) and hose to make it all up, IIRC less then $100 all up for a 4cyl.

Hope that helps.

[gromit]

Not a difficult job really just need to be careful of the clips, I would just get an oring kit and match them.

Getting the cable tray out was 'interesting'.
Removed a couple of the injector plugs, cut cable ties, after several attempts used brute force and the plastic survived. Worked out a way of re-installing without too much need for more brute force.

The O-ring was badly twisted and broke on removal. Material is blue so possibly Flourosilicon which has good temperature resistance.
Recently had problems sourcing O-rings for a Coleman stove, it used one Viton and one Flourosilicon. Local O-ring supplier couldn't help with Flourosilicon.

Hunted through O-rings in stock, found one that fitted but cord diameter too big, found another that fitted with a stretch, I could feel a resistance when the connector was plugged back in so NBR fitted for the time being. I'll take samples to the O-ring supplier I use and try to get a match in Viton.

The problem connector was the rearmost one so very little room to work, dropped the retaining clip once and luckily used a magnet to retrieve it. Found it best to part install the clip before plugging in the spill line connector then push the clip home.

Onto more household chores now, maybe some time tomorrow to work on projects......


Colin

[gromit]

I used Diesel Systems in Cheltenham (https://www.dieselsystemsaustralia.com.au/) to redo the fragile plastic leak off connectors on the Pug Hdi a while back. While they didn't specifically list the parts for the Puegeot, Ford parts are same, and in effect mine were just Bosch type fittings(as opposed to Seimens in some instances).


Thanks,
I might give them a try for the correct O-rings.

Colin

[gromit]

LR part number is LR019118.
The NBR O-ring is holding up, local supplier thinks the original is Viton (they did a hardness test).

Colin

[Cjross1983]

Getting the cable tray out was 'interesting'.
Removed a couple of the injector plugs, cut cable ties, after several attempts used brute force and the plastic survived. Worked out a way of re-installing without too much need for more brute force.

The O-ring was badly twisted and broke on removal. Material is blue so possibly Flourosilicon which has good temperature resistance.
Recently had problems sourcing O-rings for a Coleman stove, it used one Viton and one Flourosilicon. Local O-ring supplier couldn't help with Flourosilicon.

Hunted through O-rings in stock, found one that fitted but cord diameter too big, found another that fitted with a stretch, I could feel a resistance when the connector was plugged back in so NBR fitted for the time being. I'll take samples to the O-ring supplier I use and try to get a match in Viton.

The problem connector was the rearmost one so very little room to work, dropped the retaining clip once and luckily used a magnet to retrieve it. Found it best to part install the clip before plugging in the spill line connector then push the clip home.

Onto more household chores now, maybe some time tomorrow to work on projects......


Colin
How did you put the retaining clip back on. Driving me crazy.

[gromit]

How did you put the retaining clip back on. Driving me crazy.

From memory part install the clip, push home when fitted.
The NBR O-ring is still holding up.

Colin

[haydent]

My tips and parts details here Injector Return Pipe: Clip Removal and Orings Part/Sizes (Tips) (https://www.aulro.com/afvb/l320-range-rover-sport/302111-injector-return-pipe-clip-removal-orings-part-sizes-tips.html)