Disco 2 Starting problems and cutting out

hipwell said:

Can the injectors be levered out without removing the rocker shaft as per this guide?

From what i can work out he only had to remove the rocket shaft as the tool he used to get the injectors out is massive. If I use an l shaped Allen key can you get them out without dismantling the rocker shaft?

http://www.discovery2.co.uk/Injector Seals.html

Click to expand...

The rocker shaft has to come out the rockers go over the injectors, look at the picture when the rocker cover is first removed.
what he is manipulating in the write up is the cam shaft you will find that two of the injectors can't come all the way out because of the cams obstruct them, you have to first get out the clear ones then rotate the crank until it allows the last two out. Rebuilding is similar, replace the ones you freed up but two different ones will be blocked by the cams turn the crank shaft until the cams allow the other injectors to go in.

Ive found Nos 1, 3,4,5 will come out with the engine at TDC and the locking pin in.
No. 2 will need the pin out and the crank turned slightly.

Cool I'll give it a go when I'm home then.

2 questions

Does the crank need locking at tdc if I'm only removing the rockers? If it does then what size drill bit will I need as I don't have the LR locking pin

Second
Can I get access to the crank bolt to turn the engine over without removing the fan? As I don't have a fan tool either lol.

Even if you lock the cam at TDC you still have to remove a locking pin to turn it to access No2 injector.
But start with the engine at TDC, you can easily see the slot in the cam as it comes round.
I did bother with a locking pin after the first time I did my seals.
I didnt want to worry about possibly dropping a locking pin down the chain drive slot!
After you remove 1, 3-5 injectors the engine will turn over quite easily, before I had the tools I removed the oil seal/cover from just in front of the cam sprocket, and used a socket on one of the cam sprocket bolts to turn the engine, but only turn the engine clockwise or you will undo the bolt!
Ive PM my number, give me a buzz if you want to talk it over.
Mark

Have a look over in the TD5 section in Engines.
Nice write up on doing the seals has just been posted!
PS Just remembered I also turned my engine over using one of the pulleys and pushing down on the belt but mine doesnt have A/C or ACE.

Thanks for all the help guys, changed the injector seals and jobs a good en!!!

Could for the life of me get the viscous fan off as the spanner I bought came as one part, so I ended up turning the engine over using one hand on the viscous fan spanner turning the pulley and then using the other had to pull on the belt which in turn moved the crank..

I tried a bar on a bolt on the cam pully but the bolt tightened slightly and the engine still wouldn't turn and I didn't want to rip the head off the bolt.
Again, anybody else In this situation, change the injector seals before you mess about with anything else like I did!!

Good result well done!
My bad on saying you could use the cam bolt to turn the engine, I did do that but it was just to turn the cam, before I put the gear on when I was doing my rebuild.