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leezg

Member Since: 16 Feb 2016
Location: Losinj
Posts: 17

Problems AFTER injector copper washer and o-ring replacement

Hi all,

I noticed my oil level rising very little, so I changed the injector copper washers and o-rings.
I didn't know about the diesel in the cylinder problem so I removed the injectors right after installing them, made sure there was no diesel in the cylinders and reinstalled them.
When all was finished I purged the fuel sysetm, started it up, let it idle for 5 min and went to sleep happy.
The next day I could hear the fuel pump was loud, but it ran good in idle.
Took it for a test fun of 1km downhill and 1km uphill, when it cut out just before I was going to park.
It would not start, started after 5-6 attempts.
Then I purged the fuel system 5 times in a row, now the fuel pump is not that loud, took it for a 1,5km downhill and 1,5km uphill drive, all was good.

Do you think I am safe or is something wrong with the copper washers and I will have to do them again?

22nd Sep 2016 8:01pm

mk1collector

Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

Should be fine, just sounds like some air in the system that didn't come out with the first purge Ray
My build thread
http://www.defender2.net/forum/topic17615.html

22nd Sep 2016 9:53pm

gazman

Member Since: 17 Aug 2015
Location: Liverpool
Posts: 652

I dont want to worry you but this happened to me. I caused it by not cleaning everything to within a inch of its life.
Essentially I left some carbon on the injector and when I put it back in I got it trapped between the cylinder head and the injector.
After a few weeks I pulled the injectors again and noticed on that cylinder washer their was a indent where I had compressed the carbon against the copper and caused pitting. It had a fan tail Mark where gasses etc had been getting past.

I cleaned the body of the injectors the second time with a wire wheel and cleaned the cylinder head with ear buds and all has been fine since 2014 - current ..... 2003 defender td5 90 (my car)
2009 - current .... 2005 zx10r

23rd Sep 2016 9:25am

leezg

Member Since: 16 Feb 2016
Location: Losinj
Posts: 17

Thanx for your replies.
I didnt get a chance to test drive much since but I crank the engine 2-3 times a day and the fuel pump sounds good.
That should be a good sign because if air was entering somewhere the pressure would drop and the pump would whine.
I will see in time...

23rd Sep 2016 7:17pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2769

If it is now driving well you should be fine.
After l replaced the diesel filter on my TD5 l purged the system and the fuel pump was louder for a short time, after that it was fine.
You can test for leaks by turning on the ignition but not starting the engine. The fuel pump will whine but the noise should stop after about 30 seconds.

25th Sep 2016 9:46am

Martin 01

Member Since: 13 Feb 2012
Location: East Yorkshire
Posts: 502

Mine did exactly the same as yours.
I had to purge it another few times then fired it up & all has been well since.
Think mine just had bit of air left in it & just needed that out.
Hope all is well now.

26th Sep 2016 4:52pm

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