 | Home > Maintenance & Mods (L322) > Howto: FFRR '02 TD6 - Change a Diesel Injector |
 
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| Joe90 Member Since: 29 Apr 2010 Location: Hampshire Posts: 6419  
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A fairly straight forward job, but a lot of dismantling required to get at the injectors, and a few tips that go against what RAVE says!
6. My leak test had identified cylinders 1 & 4 as being problematic, so picked up a couple of Britpart new injectors from Dan at Duckworths. Working on No. 1 cylinder here.
7. Remove the springclips on all cylinders for the fuel return line and gently remove the fuel return connectors from the top of all the injectors. Lay the fuel return line aside
8. Undo unions for injector pipes - I realised afterwards I could probably have remove the rubber clips and just removed one pipe, but in this instance I removed the pipes in pairs. A 17mm open ended spanner required for this.
9. Release the 8mm nut on either side of the injector clamp and remove - careful not to loose them!
RAVE now tells you to turn the torx bolt anti-clockwise to release the injector. You can try this, but most likely you will simply shear off the top of the bolts - or worse. I recommend leaving these alone. 10. Gently tap the injector clamp from side to side with a cold chisel or other suitable implement, to "release" the injector, or use a screwdriver to lever it from side to side against the union. Work it until moving easily. You should not need to apply too much force here 
11. Using a screwdriver or other suitable tool, lever the injector up, under the union and against the manifold below. Take care as the manifold is not metal. If it won't come up, try more side to side jiggling. Keep at it, the injector will eventually pop up, then you can lift it out.
12. Comparing the old with the new
(the new one has a rubber protector on the tip!) 13. I dropped some muck into the injector cavity so attachec some 22mm plumbing pipe to the end of my garage Dyson and sucked it all out.
I cleaned up the clamp ready for refit. 14. That's it, all that is required is a reversal of the above to fit the new injector, but when tightening down the 8mm nuts do this side to side to take up the pressure evenly. 15. RAVE also indicates the need to calibrate the injector using T4. Time will tell whether this is necessary, others have reported no problems without the calibration, no doubt the IIDTool will tell me if I have a problem. 16. Whilst I was at it, I had the oil filter out and gave it a good rinse out with some petrol!
Note: cannot report on "success" yet, as I await some fuel return connectors in the post to replace one that I broke when doing the leak test. Hope this helps someone, somewhere  .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember 
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE MG Midget Mk1 1962 Previous: L322 Range Rover TDV8 3.6 2008; L322 Range Rover TD6 3.0 2002; P38A Range Rover V8 1999 |
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17th May 2014 9:50pm |
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| KurtVerbose Member Since: 08 Aug 2010 Location: Les Arses Posts: 5848  
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Thanks, I see you didn't have to go to these lengths to get the injector out. |
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18th May 2014 7:05am |
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| Joe90 Member Since: 29 Apr 2010 Location: Hampshire Posts: 6419
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I was worried, knowing my luck, and the fact they had been in there 12 years, but they behaved for me, unlike my glow plugs, three of which are well and truly f*****d ! .
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18th May 2014 12:28pm |
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| stan Site Moderator Member Since: 13 Jul 2010 Location: a moderate moderated moderator moderating moderately in moderation Posts: 35628 
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nice job tim, wiki'fied. |
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18th May 2014 12:35pm |
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| Joe90 Member Since: 29 Apr 2010 Location: Hampshire Posts: 6419
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18th May 2014 1:14pm |
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| KurtVerbose Member Since: 08 Aug 2010 Location: Les Arses Posts: 5848
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I've just had my glow plugs done by Craig - 5 were not working at all, and the 6th was hardly working. It still started (just) after being parked outside overnight in -8.5�C. Just don't go anywhere very cold and you'll be ok. 
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18th May 2014 1:50pm |
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| Joe90 Member Since: 29 Apr 2010 Location: Hampshire Posts: 6419
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Ah, fuel return connectors arrived, fitted new to pipes and bolted everything back together. A bit of a struggle to start up initially but now starts on the turn of the key. Chatatatata solved! No leaks either! No complaints from Message Centre.
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19th May 2014 9:02pm |
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| Rangie4fun Member Since: 26 Mar 2014 Location: Home sweet home Posts: 167  
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Guess I was lucky to get the injector very easily out (previous owner had the engine rebuild three years ago and also removed injectors, so where not stuck or rusted).
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3rd Aug 2016 4:55pm |
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| mm289 Member Since: 11 Mar 2016 Location: Hampshire Posts: 207 
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Just to add to this, following a suggestion from CamTechCraig I loosed of the retaining nuts on the injectors about 1 turn and then started the engine.
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16th Jan 2018 11:00pm |
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| Paul thornton Member Since: 23 Sep 2017 Location: Lancashire Posts: 545
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Yep, I did the same on mine. Nice little trick. |
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16th Jan 2018 11:07pm |
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| lounge_on_wheels Member Since: 10 Dec 2016 Location: in the great land of oz Posts: 269  
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I must have been lucky all mine came out with a slight twist if the injector, non of the horror stories of others. |
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17th Jan 2018 7:38am |
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| mm289 Member Since: 11 Mar 2016 Location: Hampshire Posts: 207
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Just to add to Joe's excellent post (again), I managed to replace all my injectors really easily apart from No.1 which was absolutely solid. After hours or tapping from side to side, gently leveraging, running the engine with it loose and soaking in releasing agent it would not budge.
Took about 20 mins of faffing and banging but eventually got it to come out. It was in much worse condition than the other 5, i do wonder if they had been cleaned before but this one had missed out as it was in soooo tight...... This is the condition it was in on removal, somewhere along the line the rubber o-ring seal has disappeared as well, loads of crud in the injector recess as well, so all cleaned up and vacuumed out.
Then noticed the copper washer wasn't on the end of the injector, it was seized into the recess  Refused to come out so found a long bolt that was just the right width thread, screwed this into the washer and gave it a tug and hey presto 
So now all 6 injectors replaced, will be interesting to see if it improves the running and MPG. Cheers, Paul. 2011 TDV8 AB 2006 TD6 AB (Gone to Wales) |
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2nd Apr 2018 12:18pm |
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| Andy Member Since: 24 Feb 2009 Location: Shropshire Posts: 2944
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I’m just doing mine. I’ve got the plenum chamber off and undone the injector pipes.
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26th Nov 2018 3:20pm |
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| Joe90 Member Since: 29 Apr 2010 Location: Hampshire Posts: 6419
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Depends if you go new LR, new aftermarket, or refurbs
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26th Nov 2018 3:34pm |
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