How to refit injector seals - pictures

<span>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.</span>

<span>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.</span>

<span>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</span>

<span>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.</span>

<span>Unclip the fuel feed on the right hand side of the engine, so that any residual fuel can drain out. Catch any spills immediately.</span>

<span>Back off the rocker adjuster screws using a flat screwdriver and 13mm spanner. Start outside and work inwards, then remove the rocker shaft.</span>

<span>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.</span>

<span>When removing the injectors, any whose removal is obstructed by the cam lobe, will need the camshaft turning until the lobe clears.</span>

There are two methods of injector removal. First, we look at the official Land Rover part, LRT12-154-1, a simple sliding hammer.

<span>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.</span>

<span>Screw down the sliding hammer until fully home. It works by applying even force to the injector, when the hammer section reaches the top.</span>

<span>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.</span>

<span>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.</span>

<span>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.</span>

<span>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.</span>

<span>Remove the rubber seal, using a small pick. Original factory ones are coloured red, whereas later replacements were changed to green.</span>

<span>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.</span>

<span>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.</span>

<span>Clean the cylinder head aperture to prevent any contaminants or lumps of dirt falling into the engine when refitting the injector.</span>

<span>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.</span>

<span>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.</span>

<span>Refit the rocker shaft, tightening down from the outer ends and working in again to ensure it goes on evenly. Torque to 32Nm.</span>

<span>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.</span>

<span>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.</span>

<span>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.</span>

<span>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.</span>

<span>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.</span>

<span>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.</span>