Fuel Leaking At Injectors

[Doo]

Some may know the saga of the C4 and the engine hilarity which persisted for an Aeon or 12

So I rebuilt the lump, many new parts, but while drilling the injector caps out, I swore (a lot ) that I could see the remains of what looked like resin...

Fast forward. Engine back in, runs beautifully with 3 recon injectors and one original. Goes through the gears so smoothly, it's like a different car (compared to the years it took to change gears before).

However, no matter what I have tried, I cannot stop the diesel weeping out around the injectors And no, it isn't the pipe adapters or the leak off pipe seals. I wrapped blue roll around aforementioned parts, went for a run & came back to find them dry, but a puddle on the cam cover.

It was bad with the standard copper washers, so went for 2mm, same thing, but slightly less. Changed to 3mm and while even less leak, it's STILL weeping and smelling (not to mention the price of fuel and the mess it'll eventually make...reminiscent of Mercedes ).

I wanted to anneal the washers, but was told I shouldn't need to. However, upon speaking with a pal who deals with plant, he suggested I do anneal the 3mm washers and see if I can stop the incessant mess, smell and crackle off the engine upon hard acceleration.

I am beginning to think that the engine had been rebuilt before we bought the car as I found many signs of such. But I wonder now if I did find evidence of resin, namely in the injector caps because that would explain the funny looking substance and the mad effort it took to move them. And the fact they spun out by hand leaving the caps...

Perhaps I am mad as a box of frogs and imagining it. But I can see how someone would be forced to take such extreme measures to stop the constant flow... Doesn't do it at idle (that I can see) but take it down the hill and back, meaning you have to use the throttle & turbo, and there we have a small, but evident puddle around all the injectors

I will try annealing, but I have a question. The deep nuts that hold the injectors on my car (2007 DV6 1.6hdi) what torque setting should I be at and should I also use Loctite on the threads as I wonder if perhaps the nuts may be loosening off....

Thanks.

Doo....

[RichardW]

It probably needs new pipes, you are supposed to renew them every time you remove them...

[Huskyxantia]

Dont use any locktight , this may help

viewtopic.php?t=43505

[Doo]

Dont use any locktight , this may help

viewtopic.php?t=43505

I did loctite one adapter, but it was more to check of it was leaking... It wasn't

[Doo]

It probably needs new pipes, you are supposed to renew them every time you remove them...

What, the metal pipes coming up from the fuel rail that's harder to reach than the centre of the earth

I remember my dad working on his boat engine (a tractor engine, Ford 4D) and not once did he have to change the fuel pipes

Another cost saving for them and a headache for the average guy having to dig into the pockets

[Doo]

Was watching TikTok (of all things ) and a chap in a similar (but MUCH worse) position with leaking diesel had left it until it caused the black death

Anyway, in the comments, someone mentioned an upgrade to the brackets that hold the injectors in and I think this may be of benefit to me.

Can anyone help?

.....Marc? Maaaaaaaarrrrrrrc!

Thanks in advance

[GiveMeABreak]

I've only just seen this, but can confirm what Richard has said about replacing the injector pipes when replacing the injectors, as they become compressed when tightening, so when removing and then reusing them they can become deformed, leading to issues.

Also, as far as the injector holder components are concerned, there have been quite a few replacement parts for these as you can see:

Item (4) Cylinder 1 & 2 Pipe Harness, part: 1570G4, £74.27
Item (5) Cylinder 3 & 4 Pipe Harness, part: 1570G5, £74.27

Note RP = Updated / Replacement Part

Item (8) Engine Injector Protector, Part: 1609848080 (RP), £5.64
Item (9) Engine Injector Seal, Part: 1609848280 (RP), £3.89
Item (10) Fork, Part: 1609848680 (RP), £21.97
Item (11) Injection Holder Clamp Pillar Screw, Part: 198283, £2.83
Item (13) Circlip, Part: 1609848880 (RP), £0.42p

[Doo]

Hi Marc, thanks very much.

I can confirm I have replaced parts 7, 8, 9 & 11.

Parts 10 & 13 came with the replacement injectors.

I have a horrible feeling I may have suffered a problem when they dressed the injector seats in that they may have gone too far. But I fear I have no redress as I paid for a casher

So, if this "is" the case, am I to understand the only fix will be a replacement head and all that entails

I am 100% that 2 of the seats are mis-shapen

But this has to be a known issue and there "has" to be a fix....

[RichardW]

I can't see how the seal at the bottom can cause a diesel leak - surely if this leaking then you just get combustion blowby. Diesel can only leak from the pipe connection of the leak off pipe - given that yours appears only to leak at higher pressure (CR engines use more pressure at higher revs - and lots of it, like 1600 BAR) it's rather pointing to the pressure pipes, although maybe there is more leak off at higher revs, and more back pressure on the leak off causing it to weep?

[Doo]

I can't see how the seal at the bottom can cause a diesel leak - surely if this leaking then you just get combustion blowby. Diesel can only leak from the pipe connection of the leak off pipe - given that yours appears only to leak at higher pressure (CR engines use more pressure at higher revs - and lots of it, like 1600 BAR) it's rather pointing to the pressure pipes, although maybe there is more leak off at higher revs, and more back pressure on the leak off causing it to weep?

I had blue roll wrapped around the pipes & adaptors, they were dry as a bone, but the webbing around the injector holes fills up.

I've narrowed it down to injector 2 and that's an original. I just let it run for ages and saw it creeping, but even with a magnifying glass & a bright torch, I could see NO leakage from the pipe!!

The only other possibility is the nut holding the nozzle in place, but I tightened it myself, I know it is solid.

This is one washer I removed (to try annealing the new ones) and I think it is from number 2.... It's the head face, the injector face is perfect.

[img]

Bit pee'd off I paid to get this done though.

Thoughts?

[Paul-R]

I had a bit of trouble viewing the photo. It's better if you upload the photo direct to the forum.

[Doo]

I had a bit of trouble viewing the photo. It's better if you upload the photo direct to the forum.

If I knew how....

[myglaren]

There is a guide here.

[Huskyxantia]

Let me know who you paid and i will avoid them, id be on there case to either give your money back or have them put it right free of charge.

[Doo]

Let me know who you paid and i will avoid them, id be on there case to either give your money back or have them put it right free of charge.

Don't worry, it was miles away from you and a cash job so all my own fault (but I WILL be letting them know that Arek((made up name)) may not be as good as he claims ).

I could (and WILL) share my other experiences of Areks mates in good time...