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1.5 DCI injector or injector seal replacement - how to video

12K views 2 replies 2 participants last post by  DIYDaly  
#1 ·
Quick video on how to replace injector or injector seals on 1.5 dci.
customer complaint of fumes smell in cap, found 2 injectors blowing past seals.
put a video together on how to fix it :)

 
#2 ·
Excellent, many thanks.
I've made it a sticky.

If I may throw in a couple of points.

When a fuel system is opened, cleanliness is next to godliness.
Last thing you want it a bit of grit getting into the system.
So when you remove the pipes, pop them into a clean placcie bag...just in case.
Seal the open ends on the engine... placcie bag and rubber bands is simple.
Mentioned in the video but does no harm to repeat, do not mix up the injectors, put each in a clean placcie bag that is labeled.... wipe the dirt off first.

Don't be tempted to re-use the copper washer. New ones are semi soft and will compress to form a seal.
Used ones have work hardened and won't.

Some grease on the clean up reamer will collect swarf and help avoid any falling into the pots.
And if no air gun available, a greasy rag on a stick can be used to dab and collect swarf from the bottom of the hole.

Some people recommend grease on the coppers, some to fit them dry, all seem in agreement not to use copperslip.

The force to lock the fork pins is low...can't remember offhand what the torque is but it is low.... get too carried away and you will strip the thread in the cylinder head.... which will spoil the rest of your day.

And a warning.
Some injectors come out by hand with a simple twist.
Some like these need a little more persuasion.
I've had one that wouldn't budge with a slap hammer twice that size and a rather large hydraulic puller stripped the threaded nipple clean off... that one ended up being drilled out.
You will not know which may occur until you try.
 
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