Have seen a few topics cropping up again about injectors failing and the quicker method of dremeling the plenum to gain access to the fixing screws. Many of the guys reading this may not have a clue what it means and had the opportunity today whilst changing a single injector ( number 6) on a non turbo but the same method applies to the twin turbo.

 

So starting off with the balancer bar removed and loom pulled back.

 

 

The faulty injector can be seen a little better now

 

 

The cold run part of the idle control valve removed for even more access.

 

 

Close up it is now clear how one of the injector cap fixing screws cannot be undone due to the plenum casting in the way.

 

 

 

So now you need a dremel or something similar, my chosen weapon is an air burr remover, has a bit more kick than an electric version.

 

 

 

 

Jeff TT

Edited March 12, 201312 yr by JeffTT

So now the excess casting has been removed the screws were able to be removed easily, one tip get a real good fitting screw driver and use a small hammer to tap the screw driver when undoing the screws.

 

 

Now its not nice but with next to nothing to grab hold of, a pair of mole grips are locked onto the plastic top to pull it off.

 

 

Now with the plastic removed it reveals a steel centre section that the mole grips can be locked on to now.

 

 

So with the mole grips locked on a series of twists and pulls and it will come out, its only the rubber seals holding it in but boy are they tight.

 

 

Fitting the replacement injector needs lots of WD 40 and a firm press down, all fitted its a case of putting the rest back together.

 

 

 

A good check around once running to make sure there are no fuel leaks and its good to go, oh and its worth getting new screws and bridge with the replacement injector as they can get damaged by the dremel action.

 

 

Jeff TT

Edited March 12, 201312 yr by JeffTT

If you want to check the injector electrically you need a meter that can read low ohms level, a working injector should read somewhere around 12 to 14 ohm anYthing else and its toast.

 

Jeff TT

 

Edited March 12, 201312 yr by JeffTT

Another great "how to thread" :thumbup1: Appreciate your time on putting these up Jeff.

Do they start to fail, ie once ones gone they will ultimatly all fail?

"So now the excess casting has been removed the screws were able to be removed easily, one tip get a real good fitting screw driver and use a small hammer to tap the screw driver when undoing the screws"

 

 

I bought an impact screwdiver for this job, great tool, no screw damage what so ever. Give it a whack with a rubber mallet and it undoes the most awkward of screws! Cheap too.

Do they start to fail, ie once ones gone they will ultimatly all fail?

 

That`s the general opinion as to what I`ve been told, although not always the case. Does mean keeping a keener eye on them though.

This is so good Jeff, As you know I'm in the process now of changing no4 injector, this is so much help a great thread. On mine i check all 6 and found that 5 were 11.8/9 Ohms & no4 Open circuit. I just hope its nothing else.

 

Cheers Jeff

:bow:

Like I said on Friday when I was at zedworld......

Jeff you are a legend in the zed world!!!

Infact, have some more rep mate :)

Do they start to fail, ie once ones gone they will ultimatly all fail?

 

That`s the general opinion as to what I`ve been told, although not always the case. Does mean keeping a keener eye on them though.

 

So really once ones failed and youve done this you should be starting to think sbout a new set and pulling the plenum? Mine are so far so good, but in hindsight I could of cut all those castings out when it was off to make life easier later.

Brilliant thread Jeff. :thumbup:

Jeff did a fantastic job replacing my injector, it's not a job I would of had the nerve to do by myself. The drive home was so much more enjoyable than the drive to Zedworld. Many Thx Jeff! And thankyou Linda for the refreshments. :bow::bow::bow:

Jeff, you need to write a book mate. Another nice bit of advice and help.

Jeff, you need to write a book mate. Another nice bit of advice and help.

 

Sod that, I am going to trawl through the forum for your threads, copy them, and write the book myself, lol!

did 2 last year on mine i found a little wd40 on the injector and with a wiggle out she popped

Can I mod put this in the FAQ's section or does anyone mind if I pop a copy in there?

Another great "how to thread" :thumbup1: Appreciate your time on putting these up Jeff.

 

Seconded....

 

.....Thanks Jeff:bow:

Great thread Jeff... I also stuck a bit of catch paper under mine when a drilled out the pleneum to catch all the metal filings, stuff gets everywhere if your engines a bit mucky, otherwise a good hoover up should do....

:clap: thank you