Injector seal leaking

[Paul.G]

I have a 2007 2.2 Tdci 110/260 fwd Transit.
I did a search and cannot find any instruction video on how to change seals/injectors, if anyone can give me a link to one that would be appreciated.

I had the Airfilter box out this morning and noticed the rocker cover is covered in oil/diesel, started the engine and see slight seapage around pot 1+3 injectors, is this the injector knackered or can I change seals and the problem be gone?

Any help appreciated

Cheers

Paul

[wronghole]

Replacing clamps bolts and copper washers would be a good first move. Also a good idea to ream out injector seats to ensure a tight seal. NB use ford only parts . plenty on this forum about this.

[Altransit]

One pair of injectors are held down by a single clamp with just one long skinny bolt, which is probably why they are prone to coming undone and leaking.
Remove the bolt, take off the clamp, remove the wiring connector, fuel inlet and leak off pipes, and the injectors will just pull out.

InjectorApertures3&4 (1).jpg

If the sealing washer doesn't come out with the injector, you'll need to fish around in the bottom of the aperture to remove it. If it looks in good condition, you'll get away with just replacing it with a new one, if not, you'll need to gently ream out the base of the aperture before replacing the washer. Do this for both injectors of the clamped pair.
Refit the injectors, and the clamp, using a brand new bolt, do NOT re-use the old one, make sure you clamp it down tight, but do not overtighten. Replace connector, diesel pipes, and anything else you've removed, and the job is done

I just did the one pair on mine, but I have the parts ready to do the other pair if either of them start leaking

[Paul.G]

Thanks for the info fellas, what do I use to ream, is there a special tool?

[Altransit]

Yes, I just bought a cheap set from ebay, which included the correct size for this engine

E.G.http://www.ebay.co.uk/itm/UK-Profession ... Sw0e9UyfMI

[v8dave]

Change the little green orings on the leakoff pipe as well. They are easily damaged and usually leak air in rather than letting diesel out, the resulting air leak will give you starting problems. Lubricate them with grease or oil when fitting.

[Paul.G]

Thanks for the link, do I need to bleed the system after removing and replacing the injectors?

[Altransit]

I've done this a few times on a Focus TDCi, and once on my Transit TDCi, and never needed to bleed the system afterwards

[knobby1]

Thanks for the link, do I need to bleed the system after removing and replacing the injectors?

As Altransit says...no need to bleed a common rail system....it's self bleeding.

Lord Knobrot

[Paul.G]

Thanks for all the help chaps, it was dark when I got home tonight so hope to get a chance to have a closer look tomorrow, living in Shetland we dont have as many suppliers as on the mainland, is there a part number anyone has for a seal kit please?

[Altransit]

Take your pick:-

eBay listings

But you'll need to order the bolts from a Ford dealer, part No.1673999 (don't buy their copper washers though)

[Paul.G]

I went to the only Ford dealer in Shetland and the seals are £13+vat each so went to the only Motorist shop on the Island and they wanted £37+vat each, I got home and looked on ebay and there is a kit with 4xblack seals, 4xcopper washers and 4xgreen leakoff O-rings for £38ish, anyone know if the ebay kits are good quality?

[t0m541]

I bought this kit from eBay and they seem perfectly ok
http://www.ebay.co.uk/itm/282165749084? ... EBIDX%3AIT
£28 with free p+p

[Hovervan]

You can get the copper washers at every authorised Delphi workshop or reseller for around 2€ each. The seals in the cam cover are avaliable on aftermarket; my were from Corteco if I remember it correctly...

Sometimes I think the Ford parts man has a giant dice behind his counter, with about 20 sides from 10 to 1000 €, and whenever you need a part he just throws it...

[Paul.G]

Tom that looks like the kit I saw but think the black seals had a tab at either side, the van is my everyday transport and not sure which are right for my engine till I start taking everything apart.

I couldn't hold back laughing when they told me the prices per seal

I think I have coolant leaking into the oil now too as the oil filler cap has creamy sludge in it and it is looseing coolant.