 | Home > Puma (Tdci) > 2.4 Injector Removal Process - replace fuel lines? |
 
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| WhathaveIdone! Member Since: 04 Feb 2016 Location: Sakhalin Island Posts: 27   
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I read around a bit and came to the conclusion that I would reuse the fuel lines. I did get a set of genuine ford fuel line protective caps and made every effort to keep things clean and everything still seems to work after almost a year now. As I took the lines off I installed the caps and bagged everything up in zip lock bags, including the injectors. Obviously cleanliness is critical, but also protecting the sealing faces from scratches or dings.
I didn't have too many problems pulling the injectors - two came out easily and the other two were more difficult but I was able to lever them out with a paracord sling wound under the strongest part of the injector, a 2x4 for levering off the AC compressor mount and a bit of a shoogle. The injectors themselves should probably be replaced, but decided not to do them at this time - there was some mild deformation of the injector tips. I didn't try cleaning anywhere near the tip as if I have understood correctly the risk of plugging the microscopic holes is too high. My injector seats were in poor condition and had been eroded by the blowing gases, so I cut them back to get a smooth surface. One of them in particular had an imprint of the hex shape from the bottom of the injector where it had been hammering. The copper washers were deformed and driven up around the base of the injector and one was left in the injector seat. Was all a bit time consuming - access is rubbish as it is right in the centre of the engine bay - you have to spreadeagle on top to see down the injector wells and I was doing it outside in -20C. Reinstallation went ok - tried to approximately follow the torque recommendations for the fuel lines by using a known length wrench and a scale just to get a feel for it but I wasn't too fussy. Haven't had any leaks yet. If you do pull the injectors it is worth checking the injector wells for remnants of copper washers and damage to the seat. Depending on how long the problem has been developing you may have some work to do. I also saw a recommendation somewhere to use a clean sheet of paper placed on top of the injector lines to check for small leaks after reinstallation - waving your hand around when you have diesel leaking from a high pressure system is obviously a no-no. Pic of the worst injector seat and injector tip in link here Best of luck! |
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16th Jan 2017 1:25pm |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127  
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I've done a few, and my own reusing old fuel lines, if you want to get new ones for peice of mind then do so.
Just don't over tighten them, that's when your problems start by introducing small particles of swarf into the fuel rail. Replace the green O rings on the injector leak off caps, they harden with age, Get genuine ones, either Ford dealer or LR, I have yet to find an aftermarket O ring which is exactly the same size. The leak off pipes come off by pulling the little slide to one side, then pulling them up and off, you will then see the O ring. 
 Click image to enlarge 80" 80" 86" 88" 90" Wanted, Forward Control Anything considered. |
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16th Jan 2017 2:25pm |
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| agentmulder Member Since: 16 Apr 2016 Location: Outer Space Posts: 1324 
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Good info.
Thanks gents. Do you have a part # for those O-rings by any chance? I'm still in two minds about DIY, but I can always give the parts to a mechanic if I decide to go down that route.. Solved the bowel problem, working on the consonants... |
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16th Jan 2017 7:00pm |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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Not to hand, sorry.
Universal part for the TDCI engine though, So Peugeot, Ford, LR all the same. 80" 80" 86" 88" 90"
Wanted, Forward Control Anything considered. |
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16th Jan 2017 8:25pm |
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| agentmulder Member Since: 16 Apr 2016 Location: Outer Space Posts: 1324
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All good, just that it isn't on the diagram above, so I'm not sure where to start looking for it..
Aside from fuel injection, what system would it belong to? I'll try some transit forums in the meantime Solved the bowel problem, working on the consonants...Last edited by agentmulder on 17th Jan 2017 5:12am. Edited 1 time in total |
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16th Jan 2017 8:55pm |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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You need the diagram for the plastic leak off pipe work.
If you look closely at the tops of the injectors, you will see the 2 pin plug on the side, The leak off pipes push directly in the top of the injector, this is where you will find where the O rings live..  80" 80" 86" 88" 90"
Wanted, Forward Control Anything considered. |
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16th Jan 2017 10:08pm |
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| Rickydodah Member Since: 14 Jul 2014 Location: East Sussex Posts: 1091 |
I'm not entirely sure whether this would help
http://www.ebay.co.uk/itm/4-x-Back-Leak-Of...6016.l4276 I started with nothing and still have most of it left! |
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16th Jan 2017 11:41pm |
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| agentmulder Member Since: 16 Apr 2016 Location: Outer Space Posts: 1324
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So on closer inspection I think the o-rings are in the picture above, but are only included in the assembly item '2' (LR005749):
How did you source them individually? Via Ford? The ones in the ebay picture look promising, but I need to open the rocker cover to compare: Click image to enlarge As they are the complete connector it makes me wonder that instead of disconnecting the connector to expose the o-ring, why not just disconnect via the pipe of the current connector, which you'd have to do anyway if you wanted to install the ones from ebay... It's done 65,000mi, imagine I didn't replace them, and had an issue - what would it be, worst case? Solved the bowel problem, working on the consonants... |
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17th Jan 2017 5:29am |
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| agentmulder Member Since: 16 Apr 2016 Location: Outer Space Posts: 1324
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Meanwhile, I've had a think about the high pressure fuel lines, Ian's comment re. swarf makes me think that maybe the unions are designed to work a little like copper washers, but instead of the washer conforming/comprissing it's more like the threads are?
In that case I can see how they would be single use... Maybe my theory is off though ? Solved the bowel problem, working on the consonants... |
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17th Jan 2017 5:32am |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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O rings are available as separate parts from Ford.
Not sure how a LR dealer will sell them? Regarding the swarf issue, I have had one line that the threads "picked up" when assembling, Go gentle with them make sure you start them by hand and they screw on easily and freely, sometimes they go tight within a few turns.. I think this one case I had was just unlucky? It was on a second hand TDCI engine used as a replacement, and I know for a fact that they had been on and off a few times. If needed get the whole leak off assembly, the pipes are small and hard, which makes replacing them difficult. The plastic caps are delicate and won't take much to break. 80" 80" 86" 88" 90" Wanted, Forward Control Anything considered. |
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17th Jan 2017 8:19am |
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| agentmulder Member Since: 16 Apr 2016 Location: Outer Space Posts: 1324
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^^
I imagine they'd sell them like any other FoMoCo part and label it 'Land Rover Genuine' and sell it at twice the price... Looks like the Ford part number for the o-rings might be '1348625' - their description is "'FUEL RETURN O-RING INJECTOR SEAL TRANSIT MK7 2.2 2.4 TDCi 2006/14" - and they are little green jobbies
Searching for the fuel lines now too Solved the bowel problem, working on the consonants... |
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17th Jan 2017 8:22am |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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That's the ones
80" 80" 86" 88" 90"
Wanted, Forward Control Anything considered. |
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17th Jan 2017 9:03am |
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| HardCharger Member Since: 03 Mar 2013 Location: Manila, SFO, Amsterdam Posts: 673 
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So the green o-rings are the injector seals?
Do you also happen to have the part number for the copper washer? It's just one copper washer and one injector seal per injector, ja? |
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21st Nov 2017 10:20am |
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| ian series 1 Member Since: 17 Nov 2014 Location: south Posts: 3127
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No,
They are the seals for the leak off pipes on top of the injectors. See where they would sit in the top of injector. Click image to enlarge Click image to enlarge 80" 80" 86" 88" 90" Wanted, Forward Control Anything considered. |
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21st Nov 2017 10:32am |
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