Is my 300tdi injector leaking???

My 300 tdi with 228k miles appears to be weeping diesel from around number 3 injector. It is difficult to see exactly where the actual leak is ,however it is very minimal and not from the pipe union.

Is the injector body shot and leaking back up via the cylinder head?
The fuel seems to magically appear around the little clamp pin in the head.

Could it be the copper compression washer is shot and some fuel is being forced back up past the injector?

Last of all, once the injector clamp is removed will the injector come out or will it be seized due to the old dissimilar metal corrosion.
:rolly:

Have you checked the leak off pipes. Given the mileage I would suggest that might be the first place to start. These get brittle with age.

terryds said:

Have you checked the leak off pipes. Given the mileage I would suggest that might be the first place to start. These get brittle with age.

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Top answer mate. Repalce the lot to be sure.

sprintmaker said:

Is the injector body shot and leaking back up via the cylinder head?
The fuel seems to magically appear around the little clamp pin in the head.

Could it be the copper compression washer is shot and some fuel is being forced back up past the injector?

Last of all, once the injector clamp is removed will the injector come out or will it be seized due to the old dissimilar metal corrosion.

Click to expand...

From what you describe it doesn't sound like the leak-off pipe, if that was split you'd have fuel running down from the top of the injector.

It is possible that your copper seating washer isn't doing its job. The injectors can be fairly tight in the head, but they should not corrode. There is a correct slidehammer tool which screws onto the pipe union, to get them out. Whatever method you use, do not rag them with mole grips, as you can damage the seating face for the leakoff pipe.

Here's some photies of me 200tdi, might be simillar tae yours, to give ye an idea ( sorry no write up yet)





































Just be carefull when ye stick the banjo bolts back in and use the correct torque settings as the bolts can very easily snap if over tightened. Best get a couple of spare ones when ye get some new copper washers just incase

Thanks Landyman,

The leakoff pipes are new so I will try removing the injector and hope it comes our ok.
If it is tight I will make up a puller in my work without any problems.
have another disco for spares to pinch an injectors from as I reckon it needs new ones by now.

Best way i found to remove em on my 300tdi as i couldnt get hold of a slide hammer anywhere was put a (think it was) 11mm spanner open end where the clamp was, spray with wd40 and keep going from side to side, after a couple of mins and a bit more wd40 they get loose enough to pull out, as said before though , dont use mole grips on the top end unless you are binning em