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How to refit injector seals - pictures

by: Auto Express team

27 Sep 2017

Go to: How to refit injector seals

Remove the plastic acoustic cover and the breather hose, preferably using the correct spring clip tool. Tuck the breather hose out of the way.
Undo and remove the rocker cover bolts. There are 13 of them, and there’s also a bracket at the front that comes off with one of the bolts.
Remove the rocker cover, then unplug the injector harness on the front right of the engine. Check for any undue oil present in the connectors.
Unplug each injector, then remove the injector harness. Each injector has simple clips, but they can be delicate, so take care not to damage them
Remove the fan cowl. Then, using the two correct viscous fan spanners, undo the fan. It will be tight, with a conventional right-hand thread.
Unclip the fuel feed on the right hand side of the engine, so that any residual fuel can drain out. Catch any spills immediately.
Back off the rocker adjuster screws using a flat screwdriver and 13mm spanner. Start outside and work inwards, then remove the rocker shaft.
Undo and remove the five injector clamps in turn. A magnetic pick-up is useful here to aid removal and to avoid them dropping into the head.
When removing the injectors, any whose removal is obstructed by the cam lobe, will need the camshaft turning until the lobe clears.
There are two methods of injector removal. First, we look at the official Land Rover part, LRT12-154-1, a simple sliding hammer.
Simply slide each half down the head, around the injector. Then, drop over the collar so it locates around both sides of the removal tool.
Screw down the sliding hammer until fully home. It works by applying even force to the injector, when the hammer section reaches the top.
The injector should pop out without hassle. It may need a few blows, so start gently if in doubt, and slowly increase the force used.
There are two seals that we need to change: a copper one near the injector tip, and a rubber seal at the top of the injector, that seals to the head.
There’s a unique code to each injector, so keep each injector in order for refitting, to avoid the need to recode them to the vehicle afterwards.
Remove the copper washer using pliers. You may notice the centre hole has become oval, suggesting that it is past its best and needs replacement.
Remove the rubber seal, using a small pick. Original factory ones are coloured red, whereas later replacements were changed to green.
Clean the injector using brake cleaner. Take care not to damage the tip when removing any carbon from around the tip. Scrape off using a pick.
Refit the new copper washer, ideally using the correct tool to ensure it goes on square. Refit the new rubber O-ring seal, using oil to lubricate.
Clean the cylinder head aperture to prevent any contaminants or lumps of dirt falling into the engine when refitting the injector.
Carefully work the injector down into the aperture in the head. Take care not to pinch the seals, or to knock them or dislodge them.
Torque down the injector, to 32Nm. There is no particular order, but we worked from front to back – it’s always best to work in a logical order.
Refit the rocker shaft, tightening down from the outer ends and working in again to ensure it goes on evenly. Torque to 32Nm.
One injector at a time, rotate the crank so the lobe is on full lift. Set the rocker by bottoming the adjuster, then wind back one full turn and tighten up.
Clean and inspect the injector harness for splits or damage, then refit. It simply clips back in, but ensure every injector is fully clipped on.
Refit the rocker cover, ensuring the rear locates in the hole. Inspect the gasket for signs of failure, and replace with a new one if necessary.
Refit breather, fuel line, and engine cover. To prime fuel system: ignition on, press throttle 5 times. ECU will run tank pump; when it stops, start up.
NJECTOR REMOVAL TOOL: You can make an injector removal tool using a large allen key, as used by the technicians at Gaydon. File the short end to a tapered 6mm point.
Place it under the injector and lever it out. The downside is if carbon build up makes an injector stubborn, you could damage the head.