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taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

2004 Defender 110 Td5 DCPU Stornoway Grey

Appaloosadude:

Yes, I have the correct TD5 injector puller and the timing pin. Dont really need the pin, but I like to start everything from TDC anyway!

You do indeed have to pull the injection rocker shaft as the lobes control the injection timings. It's pretty easy. Loosen locknuts and slacken off the adjusters as much as you can, then in correct sequence, slowly undo each rocker bolt bit by bit (I like to work in quarters). Eventually it'll loosen off and just put it somewhere clean and out the way!

The adjustment is the setting of the lobes when injectors are back in place. The injectors (including the springy bit and solenoid) all come out in one piece. You have to rotate the engine to move the valve rocker (you dont need to remove this one) out the way of the injector body sometimes as the lobes will catch. Just remove the viscous fan (again, using the correct tools) and use the crank pulley bolt to rotate.

Once the injectors are in, you bolt-up the injector rocker then wind down the adjusters. Keep going until there's no more adjustment left in the screw, then back off a turn. Dont just go from where the ajuster is loose to where it first hits the seat on the spring. You need to keep winding in until it bottoms the spring out completely, then back off. It will get quite tight and it's an arse with oily hands on the screwdriver, but you'll get there.

Once you've backed off a turn, then you need to do up the locknuts without turning the adjuster, though they're usually under enough tension not to turn, but I have some vortex sockets that screwdrivers can go through! use a dab of tipex or a sharpie to mark them so that when you do the locknuts up you can tell if they've moved.

As to the tool. If you can drop me a deposit of the cost of the tool, I can post mine to you, then when it's returned I will return the deposit etc. There's a certain element of trust involved but the offers there. Same for viscous spanners.

On a side note, the TD5 isn't strictly Common Rail though it does source the fuel from one input source. They're technically 'Unit Injectors'. Just a quick side note anyway, hope you dont mind me mentioning it. Don't mean any offense, just thought it'd be interesting!

I'm not very good at writing stuff, but hope it helps in some way!

18th Jul 2014 11:49am

appaloosadude

Member Since: 17 Oct 2012
Location: Buckinghamshire
Posts: 630

Thanks. The bit I can't get my head around,( although I think I just did whilst typing this) is, what cam is it that conflicts with the injector when trying to remove. I think I've realised that the injector spring is under compression at the moment when the cam turns over it, thereby creating the clearance which is not present when the injector rocker is removed...

I would happily pay the tool, and postage, and some beer tokens! Please send me a PM with your mobile number, so I can sort something out.

18th Jul 2014 2:03pm

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

It might be easier to stop calling the injector cam, a cam!

It's a 'Rocker Arm Assembly' :p ... might just make things a bit clearer. The main cam is lower down which the rockers run off!

The Rocker shaft is a separate entity to the TD5's cam which site lower and the the right (looking from front).] This is the one that can get in the way as the lobes run very close and the bulge can sit over the top lip of the injector (without touching). This cam also runs the the rockers on the rocker shaft which pushes the pin/adjuster down onto the unit injectors.

This image might help clear things up:

21st Jul 2014 8:08am

appaloosadude

Member Since: 17 Oct 2012
Location: Buckinghamshire
Posts: 630

Nice one!

Note to self, not a cam, repeat, not a cam.

21st Jul 2014 8:36am

Jim_Bean

Member Since: 10 May 2011
Location: Staffordshire / Shropshire border
Posts: 613

2013 Defender 110 Puma 2.2 XS CSW Santorini Black

Hey Taaz

Any news on the white smoke issue? Resolved? Clue what it is?

21st Jul 2014 8:04pm

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

Yeah ... I dont look in the mirror :p ...

But on a serious note, it seems to have cleared up for now so will be keeping an eye on it!

21st Jul 2014 9:36pm

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

Might get a small whisper, but it might just be me looking a bit to hard if you get me!

21st Jul 2014 9:36pm

Trossachs turbo

Member Since: 14 Jul 2012
Location: Perthshire
Posts: 21

Has anyone used a non land rover injector removal tool such as FoxHunter 14 PC Injection Puller Set For Bosch Delphi Deso Siemens Diesel Injectors Removal Tool Extractor.I am not sure of the dimensions. The correct tool is on back order with most suppliers. I have tried all the normal tricks ie paint roller handles cut and bent, Allen keys. Any help appreciated

11th Aug 2014 12:38pm

taazzukcb

Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

If you can get dimensions of the sets your looking at I can measure my OEM tool up.

11th Aug 2014 1:00pm

Trossachs turbo

Member Since: 14 Jul 2012
Location: Perthshire
Posts: 21

Thanks Tazz,I managed eventually using two 9inch roller handles cut down and positioned either side of the saddle of the injector,then a block of wood to bang them up together. All out and refitted, just to adjust and test.Thanks for the offer

11th Aug 2014 4:41pm

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