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trickster5000



Member Since: 12 Dec 2015
Location: East Yorkshire
Posts: 502
United Kingdom 1989 Defender 90 300 Tdi CSW Arles Blue
300tdi Injector Leak
Hi all,

I had to replace the head gasket on my 300tdi and I've now put everything back together. Started OK, but I could feel blasts of air coming from around injector #3. I bought the complete gasket set which included new copper washers for the injectors which I put on. I suspect I have put the new washer on the wrong way round as they are slightly concave on one side.

Can anyone advise me which of the two orientations below is correct?


Click image to enlarge


Click image to enlarge

I put them on as in the first photo, if this is the correct way, is there anything else that can be done to stop the blowing? Matt.

'89 90 CSW with a 3.5 V8 conversion (WIP) - http://www.defender2.net/forum/topic46809.html
Post #545895 4th Jul 2016 9:40am
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shaggydog



Member Since: 12 Aug 2012
Location: Kent
Posts: 3347
United Kingdom 1991 Defender 110 200 Tdi USW Arles Blue
Silly question but are you sure the old washer came out? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter Very Happy
Post #545931 4th Jul 2016 12:24pm
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trickster5000



Member Since: 12 Dec 2015
Location: East Yorkshire
Posts: 502
United Kingdom 1989 Defender 90 300 Tdi CSW Arles Blue
Yep, definitely came out Matt.

'89 90 CSW with a 3.5 V8 conversion (WIP) - http://www.defender2.net/forum/topic46809.html
Post #545943 4th Jul 2016 1:39pm
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dorsetsmith



Member Since: 30 Oct 2011
Location: South West
Posts: 4554

Click image to enlarge

make shore that washer seat properly over the injector tip also make shore at the injector port hole is clean and the seal washer seat at the bottom of the injector port hole are clean and free from carbon so the copper washer seat metal to metal if you are using old copper washer you will need to anneal them to soften them for reuse

Post #546071 4th Jul 2016 9:06pm
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trickster5000



Member Since: 12 Dec 2015
Location: East Yorkshire
Posts: 502
United Kingdom 1989 Defender 90 300 Tdi CSW Arles Blue
Problem solved! Smile

I borrowed an injector bore cleaning kit off our local garage and used it to clean all the carbon and oil off the bottom of the hole so that the copper seals sit better. Put all the injectors back in and now it runs great - all ticking sounds gone! Thumbs Up Matt.

'89 90 CSW with a 3.5 V8 conversion (WIP) - http://www.defender2.net/forum/topic46809.html
Post #546233 5th Jul 2016 2:09pm
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shaggydog



Member Since: 12 Aug 2012
Location: Kent
Posts: 3347
United Kingdom 1991 Defender 110 200 Tdi USW Arles Blue
Was going to be my next suggestion Embarassed

Glad you got it sorted Thumbs Up Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter Very Happy
Post #546510 6th Jul 2016 11:49am
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