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WhathaveIdone!

Member Since: 04 Feb 2016
Location: Sakhalin Island
Posts: 27

2007 Defender 110 Puma 2.4 SW Tonga Green

Advice sought - injector well cutting and injector re-use.

I have recently acquired a defender Puma that has had a hard life. I identified early on that the injectors were blowing - I was struggling to tell exactly which ones as there was crud all over the top of the rocker cover. I have successfully removed the injectors (not without issues) and have managed to clean up the injector wells after improvising a plug.

The injectors and injector wells in cylinders 1 and 2 were fine. The bolt securing cylinders 3 and 4 was in poor shape (bent / starting to crack) and the copper washers had been extruded. Having now removed the injectors and the remains of the copper washers from the bottom of the wells, it is clear that #3 injector well is in poor shape and has an imprint from the bottom of the injector in it, probably because the previous owner 'fixed'it by overtightening the bolt.

Injector well #3:

Click image to enlarge

Remains of copper washer - extruded out:

I would appreciate advice on the following:
- are there any dimensional checks I can perform after dressing the bottom of the injector well to verify that it will still seal after rework?
- are there any workarounds (thicker washers / shims under clamp) in the event that the injector well is deeper than design?
- I noted some small deformation of the nozzle tip on a couple of the injectors. The sides of the injector nozzle are no longer perfectly parallel. Is this acceptable or is any deformation cause for replacement? I was planning to reinstall them and give them a go on the basis that they were working previously.

#4 injector - washer extruded around injector.

Click image to enlarge

- Is there anything else I should inspect while I have the rocker cover off that would be useful?

Any tips or guidance appreciated!

29th Feb 2016 12:49pm

R1200GS

Member Since: 12 Jul 2015
Location: Hampshire
Posts: 265

2016 Defender 90 Puma 2.2 XS CSW Keswick Green

Can anyone help?

Looks like this chap is a very long way from any LR dealer !

2nd Mar 2016 10:36am

Fatboy Slim

Member Since: 04 Feb 2008
Location: Bridgend
Posts: 1006

Got to be worth trying to reclaim the seat with something like this :

https://www.bodyshop-tools-supplies.co.uk/...GwoddzAHMg

2nd Mar 2016 11:26am

martinfiattech

Member Since: 13 Nov 2013
Location: leicester
Posts: 422

You could flat the base of the injector port as described, I would 'ent take to much metal off.
As this will lower the injector further into the combustion chamber, this may cause impact between the injector tip and piston. The injector may run to hot.

Are you able to measure the depth of a good injector hole vs the damaged one, then try your local Diesel injection specialist to see if they can obtain a thicker copper washer.

This will correct the hight of the injector within the engine it`s self, whether the injector its self is any good is the next question.
Only other option I can see is remove the cylinder head, and see if a specialist can machine a section off the base of the port and then add a small section to make up the difference.

Being tight, my self I would try a thicker washer first. Excuse the spelling I`am better with spanners and wires.

2nd Mar 2016 4:15pm

WhathaveIdone!

Member Since: 04 Feb 2016
Location: Sakhalin Island
Posts: 27

Well won't be getting to much done until I the weekend - I have a seat cleaner coming similar to the link posted above and I'll give it a go once it arrives. Will be interesting to see how it goes.
Will probably have to do a bit of digging first....

Click image to enlarge

Will try and measure the amount of material i remove before i put it all back togethe, for future reference and in the event that the problems continue.

3rd Mar 2016 11:42am

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