Injector change on a 1.9 td

[gumby6371]

Got myself a set of fire seals and copper washers to cure a fuel leak on my 1.9td. Changed the main culprit last night so only 3 to go. However getting the old copper washer out was an absolute git, ended up having to persuade it with a hammer and screwdriver until I could bend it to get it out, any thoughts on an removal method which doesn't run the risk of dropping bits of copper into the head???
Also what socket/tool can I use to get the injector with the sensor out and will fit onto a torque wrench???
I don't think the other injectors are actually leaking but as I have new seals I thought I'd change them anyway. Going to pick up some degreaser at the weekend and give everything a good clean, very hard to spot whats leaking as my engine bay is plastered in oil and diesel at the moment

[jasper5]

When I change the injector seals I firstly remove the injector, then get a round stick covered in grease (an old valve grinding stick) and poke around the injector hole to stick all the dirt and dust onto the grease covered stick. Next I use a flat blade screwdriver that won't fit all the way through the hole in the copper seal, knock it in the hole so that it is wedged in the seal then simply pull out the srcewdriver with the seal stuck to it.

[ally406]

Hi Gumby, a proper injector socket should have a hole for the sensor cable. I presume you are attempting this job with a normal type socket?

In the past I have struggled to get injector seals out. You have to be very careful not to damage the surrounding bits of the head. I found getting a bit of PVC pipe that fits the injector hole allows me to get a screw driver down there and level it out. The PVC pipe protects the head from damage.

As for dropping anything in, it shouldn't go far as it will drop into the pre-chamber. While not ideal, I would imagine that anything you drop in should come back out again with a pair of tweezers or similar.

[ally406]

Another thought, did you check the leak-off pipes on the injectors? It is very common for the leak-off bung at the end of the chain to degrade and leak. The problem is that diesel pools at the bottom of the injector, possibly making you think the injector seal itself is faulty. When you refit the injectors, I would just replace all the rubber leak-off pipes as a matter of course, they're buttons from the dealership.

[gumby6371]

thanks for the responses, I've already changed the leak off pipes and cured most of the leaks but the one injector actually had fuel and air bubbling at the base under revs. New seal and washer fitted and has stayed dry after a good blast down the motorway!!!

I used a deep reach 27mm impact socket with no slot for the sensor cable, tbh I may not need to change any more seals, all depends on whether the fuel returns after I give the engine bay a good clean this weekend.

I'll be picking up a can of gunk from halfords on saturday as the block is plastered in old oil from a rocker gasket leak that got left way too long.

Once it's nice and clean I'll be able to locate any other leaks and fit my nice new bottom mount that's currently sitting in the boot without getting completely covered in crap. (Not looking forward to removing the drive shaft but needs must)

[ally406]

Good stuff, nothing like an oil tight engine! Yes, the middle shaft bearing can be a massive pain. I've never done a bottom mount, I don't suppose cutting out the old rubber and attempting to refit in situ is possible?

[gumby6371]

from what I've read on here it's possible but not advisable, pressing the new bush in under the car sounds like a royal pain in the arse.

I'll give it a good clean and make a decision, I've already got a new oil seal for when the drive shaft comes out so if it looks like it's leaking it's coming out, same with the boots, might as well change the lot in one go.

But if it's clean and I can get the new bush in who knows