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Thread: Copper Washer/O-rings & Injector Harness progress + concerns

  1. #1
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    Copper Washer/O-rings & Injector Harness progress + concerns

    Afternoon gents

    Halfway through my copper washers/o-ring and injector harness replacement. What had began as a little hard to start had progressed to very hard to start and dying whilst driving in a matter of 3 months. Thought it was just the washers at first but have located a little bit of oil in my injector harness red plug into the ECU. Not replacing whole loom just injector harness as per recommendations.

    Hoping the above fix is the root cause, otherwise I'll need a good cry!

    Concerns so far:
    • I did not find carbon/discoloration inside my injector sleeves just carbon at the bottom where the copper washer would touch
    • Washers were quite difficult to get situated and needed a socket and some light force to get them the last mm even after some fine sand paper work
    • Not much fuel came out when removing the fuel pressure regulator/return cooler quick release hoses (have organised for a pump to suck fuel out instead)
    • Have noticed some fine carbon on tip of nozzle, cleaning or even touching is a big no no or is there a trick/tips?
    • Previous owner did tell me he replaced injector 1 due to failed solenoid however it is a black injector with the rest being green! (D2a 2004 15p). Invoice I have shows Davis Performance Landrovers completed the job who according to a few sources on here have alot of experience and surely wouldnt have done this if there were any concerns?


    Any re-assurance appreciated

    IMG_20180919_151742.jpgIMG_20180919_151656.jpgIMG_20180918_200407.jpg

  2. #2
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    You can clean the nozzle external but only use a brass or nylon hand brush
    those washers look like they where sealing fine,
    what are the o rings like?
    only way to know for certain on the injector would be to have it tested and make sure its a 1700psi one not a 1500psi one,
    Customer might of supplied injector and said get it going as well,
    also inspect the injector tubes and make sure one it not cracked
    also how old is the pressure regulator as it should be holding around 40-50psi in the rail

    also make sure the seals and injector is well lubed before reinstalling so you dont nick a o ring

  3. #3
    discorevy is offline ChatterBox Silver Subscriber
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    Washer middle top has definitely failed , you need another green top injector, don't refit the black one.
    You need to remove old washers , then clean with throttle body cleaner and stiff nylon or brass brush, then fit the washers , as long as the socket hasn't marked the washers you'll be ok.
    You'll need to code the new green top to the ecu.
    Make sure the sealing face on the head for the copper washers is spotless.

  4. #4
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    Although it's not evident at a casual glance , there is a raised ridge on the injector flange about 2-3 mm from the shaft. I found I had to get a dentist probe/pick in there and scrape off all the accumulated carbon, which revealed the ridge.
    You have to be very careful and delicate.
    The ridge is what seals it.
    I think the washer second from right is stuffed.

    Regards Philip A

  5. #5
    Roverlord off road spares is offline AT REST
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    Some workshops use the 300tdi injector washers on the td5s as they have a ridge and preload better.


  6. #6
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    I annealed my washers before fitting them. Heated cherry red with a plumber's torch and quenched them.
    Probably unnecessary, but the old girl's still running, so no harm, no foul.

  7. #7
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    Thanks for the input guys

    Here are some clearer pictures of all 5 washers, Can anyone confirm if they would not have been sealing and what am I looking for? I also noticed these ones have ridges so I guess they were 300tdi ones?. I have now installed genuine land rover washers and o-rings (ERR6417 & ERR7004) Orings that came out didn't look damaged.

    IMG_20180920_084909.jpgIMG_20180920_085004__01.jpg

    Found the invoice when the black injector would have been installed and its been in for 8 years / 130,000km so I'm hoping its the correct PSI and doesnt matter all other injectors are green/

    Fuel pressure regulator was replaced 2013 / 80,000km ago

    Moment of truth tonight just waiting for a torque wrench

  8. #8
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    You look for evidence of carbon present outside the line where the injector raised portion indents.

    In addition look for areas where the indent has a different colour or evidence of overheating.

    The carbon on the inside of the line is meaningless.

    It looks to me as though several have been leaking. But it also looks like they have been handled a bit so the evidence could be misleading.
    Just make sure to clean all the carbon from inside the ridges on the bottom of the injectors as I posted earlier.
    To me LH, 2nd left and maybe 2nd from right .
    Regards Philip A

  9. #9
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    They have started to go but not real bad, looks like they have lost tension on them

    put it back together and see how it goes

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