Injector issues

Redsunsuperman666 · Oct 15, 2022

Hi Everyone
I have been having issues with my 2.4 td4 2007 Defender for a bit now and just cant seem to get to the bottom of it so any suggestions or help would be appreciated.

I will attach some pictures of my injectors but they are really bad and i only had them out a month ago to clean and inspect after having the same issues.

I have changed the copper washers, new injector oil seals, new fuel return seals and a new fuel filter.

TIA
Mark

Ratae · Oct 15, 2022

Did you use Genuine parts copper washers?

FWIW The Mercedes Sprinters have similar issues with their Bosch injectors - 'The Black Death' - & mine, a 2002 208cdi had it over a period of time with 3 of the 4 injectors. The injectors look much the same shape as yours.
There was very slight seat damage which needed cleaning up & I used one of the Laser branded seat cutter sets very carefully.
The genuine MB copper washers are very hard & I had the problem reappear very quickly on two of the injectors. It's a known fix on the MB to use genuine Honda ones which are a little thicker & much softer & I've had no further issues with those. I've no idea if the Honda ones would fit LR injectors
I do wonder whether annealing the MB ones might have done the trick as it would soften them.

Leads me to wonder if your seats have slight damage - gas cutting caused by the blowby & once cleaned up whether using genuine washers but annealing them first might help.
To anneal, heat to cherry red & allow to cool. Something I used to do when reloading bottleneck rifle cartridges & the copper head gaskets used on old British motorbikes (I have a 1950 BSA A10)
Might be of interest: www.jrcengineering.com/technical-support/annealing-copper-gaskets/

Redsunsuperman666 · Oct 16, 2022

Ratae said:
Did you use Genuine parts copper washers?

FWIW The Mercedes Sprinters have similar issues with their Bosch injectors - 'The Black Death' - & mine, a 2002 208cdi had it over a period of time with 3 of the 4 injectors. The injectors look much the same shape as yours.
There was very slight seat damage which needed cleaning up & I used one of the Laser branded seat cutter sets very carefully.
The genuine MB copper washers are very hard & I had the problem reappear very quickly on two of the injectors. It's a known fix on the MB to use genuine Honda ones which are a little thicker & much softer & I've had no further issues with those. I've no idea if the Honda ones would fit LR injectors
I do wonder whether annealing the MB ones might have done the trick as it would soften them.

Leads me to wonder if your seats have slight damage - gas cutting caused by the blowby & once cleaned up whether using genuine washers but annealing them first might help.
To anneal, heat to cherry red & allow to cool. Something I used to do when reloading bottleneck rifle cartridges & the copper head gaskets used on old British motorbikes (I have a 1950 BSA A10)
Might be of interest: www.jrcengineering.com/technical-support/annealing-copper-gaskets/

Hiya

i have noticed that not all the copper washers i buy are exactly the same so you might be right i will get some genuine ones.

cheers

myfirstl322 · Oct 16, 2022

Redsunsuperman666 said:
Hiya

i have noticed that not all the copper washers i buy are exactly the same so you might be right i will get some genuine ones.

cheers

I'd second getting a seat cutter kit anol.

myfirstl322 · Oct 16, 2022

Handy overview for you.

Wimblowdriver · Oct 17, 2022

If the injectors have been changed at any time, or mixed up when replacing them, have they been re-coded into the ECM? Using diagnostics, do you get any injector related fault codes?

craigoodwood · Oct 17, 2022

I'd be inclined to look at the engine breather system and egr setup....

Injector issues

Redsunsuperman666

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Ratae

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myfirstl322

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Wimblowdriver

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