 | Home > Puma (Tdci) > Injector seat cutter. 2.4tdci Puma |
 
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2300   
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15mm flat. Recently did mine https://www.defender2.net/forum/topic53240-120.html > 110 XS Double Cab
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14th Oct 2020 7:20pm |
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| Crockett55 Member Since: 14 Oct 2020 Location: Suffolk Posts: 5 
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Hi thanks for that was it a 15-19 flat ?
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14th Oct 2020 9:55pm |
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| skidrov Member Since: 06 Oct 2013 Location: Melbourne Posts: 56  
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Feel a bit silly questioning someone who's actually done it, but I thought I had read, especially on Transit forums, that it was 17x17 flat?
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15th Oct 2020 7:44am |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2300
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I had also read 17x17 flat on a transit website and even referenced it in the last post of this thread https://www.defender2.net/forum/topic67028.html
So I ordered a kit containing a 17x17 cutter only to find it was too large to go down the injector bore. You can see in the below photo that there is a counterbore within the injector bore around 20mm above the seat... This is where the 17mm cutter fouled. In saying this, you can see the 15mm cut diameter of the seat and there looks to be at least 1mm not cut beyond that so the 17mm should fit? Perhaps my counterbore was fouled up preventing the 17mm cutter from going down? That being said the copper seal washer is 13.5mm outer diameter so 15mm cut seat is fine. Luckily my kit also contained a 15x15 flat which did the job and I confirm my injectors are still sealed!  Click image to enlarge > 110 XS Double Cab |
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15th Oct 2020 8:32am |
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| Crockett55 Member Since: 14 Oct 2020 Location: Suffolk Posts: 5
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Interesting, I am having a few problems. My 17/17 goes down ok but seams to be cutting a ridge at the bottom and not touching the seat . I have a 15 / 19 which goes down but I seem to be taking minimal metal almost a scraping so it not cutting into the damaged seat . I’m wound sting if the 19 is bottoming some where but I can’t see where . I’m thinking a 15/15 is the way to go which is not in my set . You can see the damage caused by the injector hexagon . Last edited by Crockett55 on 15th Oct 2020 12:45pm. Edited 1 time in total |
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15th Oct 2020 11:10am |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2300
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How annoying. For info this is the kit I used which contains a 15x15 flat
https://www.amazon.co.uk/gp/product/B07TFVTWPD > 110 XS Double Cab |
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15th Oct 2020 11:43am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17390
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My Sykes Pickavant set says use the flat 15mm (but I haven't yet done this job on the TDCi myself).
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15th Oct 2020 12:10pm |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2300
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Ah nice. There's nothing in the service manual... Just says "check for blow by and rectify as necessary" > 110 XS Double Cab
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15th Oct 2020 12:26pm |
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| Moffett Member Since: 08 May 2018 Location: Sligo Posts: 69  
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What did you guys torque the stretch bolt on the injector clamp to?
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16th Oct 2020 6:38pm |
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| Crockett55 Member Since: 14 Oct 2020 Location: Suffolk Posts: 5
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New bolt ( clamps replaced is recommended) 6nm or 4lb Plus further 180deg
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16th Oct 2020 6:49pm |
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| Moffett Member Since: 08 May 2018 Location: Sligo Posts: 69
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Cheers Crocket, didn't know about the new clamps. I was going looking at this today but might order 2 clamps and do the brakes instead.
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17th Oct 2020 8:03am |
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| Crockett55 Member Since: 14 Oct 2020 Location: Suffolk Posts: 5
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Apparently they can crack they are not expensive go genuine Ford or Land Rover .
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17th Oct 2020 9:18am |
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| Moffett Member Since: 08 May 2018 Location: Sligo Posts: 69
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Well, I got up to the shed and changed the first two injector seals. What a strange job of uncertainties. The seat cutting tool is vauge fit and does not centre well. I got it to work but the majority of the cleaning was done using a rag wrapped around some nylon bar stock. The copper washers in my eBay kit were wider than those removed, but fit the bore nice flat side down as advised by Google. The springs in the oil seals HD popped out in the jiffy bag, and didn't seat well when reinstalled. I made the decision to leave them out as the rubber is a tight fit around the injector and I don't want them coming off under the rocker cover. One of the green clips on the leak back pipes is missing and replaced by a cable tie. I reinstalled everything and ordered the green clips. Washed everything down with solvent and went for a good drive. The front two injectors are dry as is the formerly leaking fuel rail. I have come to the following decision. I have ordered a different injector seat cleaning kit and am currently browsing better quality seal kits (recommendations welcome!). I am going to pull all 4 injectors and send them for testing /recon. I might replace the injector pipes also. I can see now the devil is in the detail with this job. The seat cutting tool was my main issue. I would need one that was tailored specifically to a Defender. I am going to try Laser 6101. I will only need the cutter if the seats are badly coked up with carbon.
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19th Oct 2020 7:37pm |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2300
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Totally agree with devil being in the detail!
A few snippets I can share from my (unfortunately) detailed research on this job 
OE copper seals from JLR are extortionate. They are slightly cheaper from Ford but still outrageous given what they are. Cheap ebay ones or the ones included in the chinese kits are poor quality and a false economy. When I measured mine they mic'd up thin which doesn't help in achieving a seal as they contribute to the overall length between head and injector clamp coming up short. It's definitely worth getting quality seals from a branded manufacturer. I can recommend these Elring ones from personal experience https://www.ebay.co.uk/itm/173834488507 Alternatively there are thousands on ebay if you can be arsed to browse the specification Outside Diameter: 13.7mm, Internal Diameter: 7.16mm, Thickness: 1.6mm. I like those Elring ones from the ebay link as they're slightly smaller on the internal and larger on the external giving a greater cross sectional sealing face. They're also a smidge thicker so clamp down nice. The following vehicles use the same for info. Citroen Relay 2.2 HDI 100 2006-2013 Ford Transit MK7 2.2 / 2.4 / 3.2 TDCi 2006-2014 Ford Transit Tourneo 2.2 TDCi 2006-2014 Land Rover Defender / Defender Cabrio 2.4 TD4 4x4 2007-2016 Peugeot Boxer 2.2 HDI 120 2006-2018 Ford Mondeo 2000-2014 The rocker cover oil seal springs seem too weak to do much! The oil seals are almost just splash guards keeping water out and oil spray in with a secondary function of being emergency pressure reliefs if the positive crankcase ventilation fails. My springs dislodged too but personally I did refit for peace of mind. As an aside if the springs do pop off inside the rocker cover they can't go far as they stay around the injector body and can't fall below the injector holes in the rocker arm cover (see pic below) My injector tool has a 3/8 square drive and I found that driving it with my air ratchet was helpful as your hands remain stationary which helps maintain alignment Doing it by hand the cutter shank kept binding up in the bore. I used next to no downwards force other than the tool weight and let the cutter do the work over many many rotations. More like a scraper than a cutter. Not sure about the green clips? My leak back pipes clips were metal. Click image to enlarge > 110 XS Double Cab |
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20th Oct 2020 9:02am |
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