Thread: Injector "chuffing"

wheres it leaking from, exactly, pictures will help.

Well that's the problem, I'm not sure. I think that it's around the #2 injector,I'm going to take that one out again tomorrow and check that I have got everything clean and put a new washer in, is it correct to anneal them? My training (ex Navy) says to anneal. The injector is clean,spotless, The head is new from Turner Engineering so I doubt that there is a stuff up with them, It's more likely something I have or haven't done Any suggestions looked at. Come to think of it, I had a **** of a job getting that one out, and I marked each one with a scratch mark so I know which one it was.
The clamps have the bow upwards, correct?, the clamp bolts are VERY tight.
would 2 washers help?

Thanks, Jack

tickety-boo?

Originally Posted by jacknz

Well that's the problem, I'm not sure. I think that it's around the #2 injector,I'm going to take that one out again tomorrow and check that I have got everything clean and put a new washer in, is it correct to anneal them? My training (ex Navy) says to anneal. The injector is clean,spotless, The head is new from Turner Engineering so I doubt that there is a stuff up with them, It's more likely something I have or haven't done Any suggestions looked at. Come to think of it, I had a **** of a job getting that one out, and I marked each one with a scratch mark so I know which one it was.
The clamps have the bow upwards, correct?, the clamp bolts are VERY tight.
would 2 washers help?

Thanks, Jack

No need to anneal the copper washers if they are new. Clamps bow upwards, two washers not a good idea. There are torque settings for the clamps but the leak is more likely coming from the injector connection or fuel return banjo. Is the fuel return line wet?

I recently did the exact same job with a turner gas flowed head on a 200tdi. When first started I had the same diesel leak. Mine was from the top injector feed connection and one on banjo. Undo the lines on the leaking injector and redo them with new washers and correct torque setting.

Another issue I had was snapping the clamp stud on one of the injector clamps. So dont over tighten the clamps. You have the workshop manual with all the torque settings right?

Spray some water down around the likely offender and run engine, if water gets blown up out of injector hole, it's leaking. Most injector washers (new) have a raised ridge which gets compressed when the injector gets torqued down. No amount of annealing will restore the sealing ridge. I would purchase a new set of washers/seals and install right way up, according to manufacturer, Regards Frank.

It looks like I may have the clamps upside down and a leak from a return line, I will rectify in the morning and get back to you.
Thanks

It's been a long day, My clamps are on correctly, just the fittinfs to check in the morning, i like the soapy water idea too.
Thanks

Thanks for all the suggestions, but after all that it has turned out to be nothing more than a glow plug not tight enough. I remember now that the Mrs was talking to me at the time I was fitting them and informed me that I was a grand parent for the 1st time!

Thanks for the help guys,
Jack