replacing injector washers

i posted my previous question in the wrong section before, so thought i would post it in the right one this time.

how difficult is it to replace the copper seal washers on the injectors on a 300 tdi ?

does it require much skill ? and is there anything i need to do after i have done this, bleed fuel system ect. ? or any special precautions

thanks

Rod

No worries found all the info i needed on the Rave cd


cheers

Howdy, did you find any tips - i havent got a rave cd and am planning on replacing mine soon too ;o)

Obviously if you're replacing the washers, you'll have to remove the injectors.
First undo the leakoff pipe that is connected to all of them and move it out of the way, don't pull the banjo's out of it, their washers should stay on.
Then undo all the injector pipes from the injectors, and pull them away from the injectors a little to give you some room (not a lot!)
Now undo the nuts on the clamps and lift them away, you may get some of the studs coming out, if you do, it's best to run these back in using the 2 nut method once the injectors are out.
Now you've got to get the injectors out.......... they *technically* just lift out. Practically they won't if they've been in there a few years.
The best thing to do, is to spray some penetrating fluid, WD40 or similar around the injector body, then by getting a spanner onto the flats on the injector (where the clamps where) start to turn them slowly back & forth, freeing them up, once free they'll lift out easily.
See if the copper washers come out with the injectors, if they don't, get a round file, remove the handle, and just put the tang into the hole, that'll get any errant washers left down there.

I found that 2 of my injectors were really stuck in, as I was also going to reset the tappets as well, I removed the rocker cover, this gave me much better room to get a large adjustable spanner onto the injectors to *work* them and loosen them off.
Now that you've got the injectors out, you may as well have them checked/serviced, but be aware, the parts for these are expensive, it cost me £160 for all 4 injectors to be reconditioned.
To refit with new copper washers (these will come with your injectors if refurbished) just put a small dab of grease to hold the washer to the injector prior to sliding it back into the cylinder head.
Then put it all back together, remembering not to overtighten stuff. (there'll be torque setting in the manual if you're prepared to look)

Refurbed injectors in mine has made a big difference.

You state that it's expensive to have the injectors re-conditioned, but I wonder over how many miles you'd get that cost back due to increased fuel economy?

Not meaning to come across as a bit of an arse, but perhaps it would be better to view it as an investment rather than an outright expense?

Did you notice getting more miles per tank after getting yours done?

I haven't really used it since properly for any distance as it's part of the preparation for our trip to France with MUDPLUG Mudplug's Greenlaning Adventures this weekend, with over 800 miles each way, it should prove better on fuel.
it certainly feels better on the bits of running around that i've done in it.

With diesel at £1.21 and rising, (petrolium is sold in US$, and as the €uro continues to slide, even though we aren't in the single currency, we are in the Eurozone, so Sterling will dip against the Dollor, and no Sean, this is not a dig at Labour, as every goverment since the mid 70's has had a hand in this), fuel is going to get more and more expensive. £1.50 per litre before the end of 2012? I wouldn't bet against it.

So even if your only getting a saving of 2.5%, you should get your money back within 16 full tanks, or 8500 miles.

Do any of you guys use stuff like the Red-ex or Valverline injector cleaners? If so, how often?

I do every 5000 miles, but I must confess that I have no idea if they really work or if it is just a clever marketing scam?

hi all how do you know if your injectors are in need of some servicing?? i have just done a head gasket on my 300 tdi and at the garage where it was skimmed they took all the head apart, injectors out glow plugs out etc etc wghile they were out i gave them a good scrubbing with de greaser and put them back with new washers on. how will i notice the difference if any????
cheers
oli

Just a quick question about the washers.

They have a concave side and the haynes manual says this should face towards the inector.

I am happily replacing them with the concave face upwards towards the injector a far as I am concerned, then I thought, what if they mean the bit the fuel comes out, then they need to face down????????

Can anyone shed some light for me urgently as I am in the middle of the job now.

Why dont Haynes just say face up or down, then we would know what is meant.

Have searched a little more and found the answer.

I was fitting them wrong as the ridge needs to be up against the injector body, so ridge facing up for others reference.

I fit the washers by threading one onto a flathead screwdriver shaft,hlding up by handle as you place the screwdriver into the empty injector hole then letting washer slide down into place,removing screwdriver gently.