Thread: 300 tdi Damaged Injector Seat

Originally Posted by d2dave

I have jut finished installing a SH 300 tdi in the disco. I did notice that one of the injector seats was was scored and I managed to damage another one trying to remove a stuck copper seal

So how do I repair it? Will one of these do the job?

Diesel Injector Seat Cutter SET 7 Piece KIT Cutting Tool Aust Workshop Mechanic | eBay

Saw the title Dave and immediately set off to find the part you need...
a complete replacement bolt in and bolt out... an ejector seat...

uh oh.... hold on I may have misread your post title........

F-4 Phantom II Ejection Seat : Furniture

well, if you need to get out of the car quickly might I suggest this, and a sunroof!


sorry! Digger

Is the head installed or off, if installed you will need to prevent any shavings/swarf dropping into top of piston.
How much metal do you have to remove, you may need to use 2 washers to keep the nozzle at correct depth.
If you get the piston under the injector hole up to TDC you could make up a small tube to fit on (Gaffa tape) the end of your wife's Vacuum cleaner and suck out any swarf that may get in. Or fill the bottom of the hole with some rag or paper and vacuum the swarf out that way and then dig, carefully with a bit of wire out the paper or rag.
If you buy that Kit to ream the bottom of the hole make sure they have one that suits your size hole, good luck, Regards Frank.

Thanks Tank. The head is on. Probably about 20 thou for one and 15 for the other. Is the injector that close to the piston that this bit of extra depth would matter?

My idea to keep the swarf from the cyl would be to have the piston an inch or so down from TDC.
A piece of steel rod the correct length to sit a bit below the top of the hole on the piston and jam a piece of foil in the hole on top of the rod to seal the hole.

After reaming I would hold the foil with a thin screw driver and blow out the hole with compressed air.

I would then raise the piston to remove the foil and rod.

As for the kit to do the job. Do I just measure the hole in the head and then make sure that there is the right size reamer.

How is the tool held square when doing the job?