2004 Boxer 2.0 HDi injectors

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boristhemoggy
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2004 Boxer 2.0 HDi injectors

Post by boristhemoggy »

I took an injector our with the intention of cleaning them all and noticed that the hole where it goes, (no idea what it's called) is shiny and clean except for right at the bottom where the seal contacts, and it's got a little dry carbon round there. However there was diesel on the walls of it and I wondered if that would be normal?It wasn't tons, just a light coating of it but I had to use a kitchen towel to dry it off before putting the injector back in.
Any idea if that's normal or not?
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Re: 2004 Boxer 2.0 HDi injectors

Post by Peter.N. »

Assuming this is the 8 valve engine the injectors are usually pretty bombproof and don't really benefit from cleaning, in fact if you are not careful you can damage them. You should use a new seal when you have removed an injector but you might get away with it if its perfectly clean.

If there is any carbon round the injector body then the seal is probably leaking so a good clean and new seal should do the job, diesel fuel probably ran down from the injector when you took it out unless there is any indication of a leak.

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Re: 2004 Boxer 2.0 HDi injectors

Post by boristhemoggy »

Cheers Peter. 3 of the injectors were carboned up pretty badly, one was covered in white powdery deposit. All the glow plugs were also in an awful state. Others have said 1 at least may be leaking under pressure but I was going to replace them all as my mileage is poor.
Yeah new seal each time, just cos they're about 50p each lol
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Re: 2004 Boxer 2.0 HDi injectors

Post by ekjdm14 »

boristhemoggy wrote:Yeah new seal each time, just cos they're about 50p each lol
Sensible man... Not like me lol I've been known to reuse head gaskets!
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Re: 2004 Boxer 2.0 HDi injectors

Post by Peter.N. »

A bit off topic but regarding head gaskets, we had a diesel Austin A60 before we moved down here, I had only had it for a little while when it started emitting a terrible knocking noise, I took the head of and found that a piston ring had worked its way up the bore, cutting a hole in the side of the piston, and had finished up on top of the piston and at the top of each stroke was trying to knock a hole in the head.

I fitted new pistons and shells and was still putting it back together when the removal van arrived! anyway although it was my wife's car I drove it down here an case there were any problems but there weren't fortunately, my wife drove our petrol Oxford estate.

About two days after we arrived I was driving the diesel in to Axminster when a very loud knock started, I put the starting handle in and could feel almost solid resistance as I turned it, I got it home, took the head off and found this time one of the valve seat inserts had dropped out and somewhat roughened up the top of the piston, anyway I found someone to fit a new insert and threw the engine back together using all the old gaskets including the head as I proposed to get rid of it, as it happened I didn't for a while and it ran completely trouble free for the rest of the time we had it.

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Re: 2004 Boxer 2.0 HDi injectors

Post by Paul-R »

This must surely have involved one of the old style copper head gaskets. I have read of people annealing copper head gaskets and then reusing them as they had their crushability restored.
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Re: 2004 Boxer 2.0 HDi injectors

Post by Peter.N. »

Yes it was the old copper type, this was done in 1970, it had only been fitted for a few days.

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Re: 2004 Boxer 2.0 HDi injectors

Post by ekjdm14 »

I will admit at this point, the only time I've reused a composite gasket on a water cooled engine was with the Xantia experiment. I have however reused composite gaskets on air/oil cooled 4 stroke bikes before with good results, in one instance I had the head off a 1981-ish Suzuki DR400 around 6 or 7 times and it still sealed...

Copper head gaskets are usually good once annealed. That sounds like quite some stress that A60 motor went through, Peter. If you'd carried on running it you might have done as good a job as was done on the aforementioned Xantia!
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Re: 2004 Boxer 2.0 HDi injectors

Post by boristhemoggy »

So anyway, can anyone suggest what the leaking diesel may be? Is it simply a bust injector?
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Re: 2004 Boxer 2.0 HDi injectors

Post by Peter.N. »

I would suspect it ran down from the injectors when you disconnected the pipes, there is normally some leakage when you disconnect the leak off's and probably the supply pipes as well.

I used one of those laminated gaskets on one of my XM estates, no problem at all for probably 70-80k until my wife wrapped it round a bus shelter.

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Re: 2004 Boxer 2.0 HDi injectors

Post by ekjdm14 »

boristhemoggy wrote:So anyway, can anyone suggest what the leaking diesel may be? Is it simply a bust injector?
I agree with what Peter suggested originally, and again above, that it most likely ran down when you disconnected the injector.

Hope the cleaning yields some sort of results
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boristhemoggy
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Re: 2004 Boxer 2.0 HDi injectors

Post by boristhemoggy »

It's definitely not that because the hole it leaks into holds about a desert spoon ful, and it's full now for the third time. It looks wet around the base of the injector and bracket too.
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Re: 2004 Boxer 2.0 HDi injectors

Post by boristhemoggy »

I eventually replaced the injector and it seems fine at the moment. Either I had not put it back together tight enough, or is might have been cracked.
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Re: 2004 Boxer 2.0 HDi injectors

Post by jimmymarsbar »

boristhemoggy wrote:Cheers Peter. 3 of the injectors were carboned up pretty badly, one was covered in white powdery deposit.


Sounds like corrosion. You might want to check the walls in the hole where the injector sits
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