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        General >> Problems >> 2.5 Turbodiesel -injectors removal-
        
(Message started by: pustagris on Apr 17^th, 2005, 12:01pm)

Title: 2.5 Turbodiesel -injectors removal-
Post by pustagris on Apr 17^th, 2005, 12:01pm

Is it possible that a injector blocks a large procentage of the fuel?
After my repair of the push rod on the cylinder in question (last seen from front) where I remarked a considerable quantity of fuel splashed around the injector before fixing the push rod I now see that the splashing is still going on.

Is there really need to have the special tool shown at http://www.fordscorpio.co.uk/manual/fuel/TDIFuelInj.pdf
if you want to take out an injector?
regards
Volker

Title: Re: 2.5 Turbodiesel -injectors removal-
Post by richardcoles on Apr 19^th, 2005, 10:46am

Hi Volker,

In answer to your first question :- it is doubtful if the fuel injector is blocked (remember injection pressures can be as much as 6,000 PSI). The fuel is probably coming from the leak off or spill pipes, these pipes carry back the leakage from the needle valve from the fuel injector body. The pipes perish and leak and this may be what you are seeing. Conversely they could possibly be a leak on the body joints of the injection valve. I had one that leaked. Lived with the problem for a couple of years then when I had a problem with the electronic fuel injector (the one with wire attached No. 1 unit) I just clipped the wire and fitted it to the offending unit. If you do not have fuel injector test facilities do not try and strip these injectors. I have found that car injectors do not seem to be repaired, the mechanics just play “swap it” engineering; if we did that at sea we would have been laughed out of the engine room.

Removing fuel injectors:- the simple answer is a special tool is not required. You need a box spanner and Tommy bar or a cut down ring spanner plus muscle power or a 2-pound hammer. Take your pick.
Disconnect the fuel injection pipe and bend it slightly out of the way, remove the rubber spill pipes. Be prepared for these to break or cut them back when refitting.
Remove the fuel injector, it will be tight, it would not be if car mechanics had heard of “copperslip” high temperature compound. Unscrew it carefully; do not damage the threads.
Refit your new injection valve (£80 for plain and £120 for the electronic type) remember to use high temperature grease and refit carefully. Ensure the copper joint is refitted.
Priming the fuel system can be fun!! Or you may be lucky and it fires on three units and the empty fuel injector will pick up on its own. If not slack back the pipe unions and turn the engine over on the starter till a steady stream of fuel oil comes out, retighten ALL unions and it should start.

Regards

Richard