I want to change O-rings on injectors. Can i do this job by myself... i have tools... but kinda worried if i may do something wrong... especially when trying to get out injectors. Did anybody do that job by himself?
Protei, I have done mine myself recently. It is an easy job to do. The most difficult bit is getting the injectors out of the head. I borrowed a lever from a local garage but I have heard some people on here say they used a set of pipe wrenches which they took apart to use as a lever (see link to picture at bottom of post.) The injectors don't need a huge amount of force to get them out, and there is a flat bit on the body to make it easier if you use a lever - DO NOT LEVER THEM OUT BY THE SOLENOID.
1 - remove plastic cover from top of engine
2 - remove rear plastic cover too (8mm socket and 8mm ring spanner)
3 - remove the pipe which is clipped onto the rocker cover (pliers)
4 - remove the rocker cover & gasket and keep them aside (8mm socket)
5 - optional release the pressure on the tappets by slackening them off (13mm spanner and a plain screwdriver)
6 - remove cam shaft (release gradually if 5 not done - 13mm socket if I remember correctly)
7 - clean the area as much as you can
8 - remove injectors one at a time and clean the hole they came out of (a small amount of fuel will probably leak into the cylinder)
9 - clean the hole the injector came out of, making sure there isn't even the slightest speck of dirt in there
10- remove the old o-ring and copper washer
11- carefully clean the end of the injector
12- smear the new o-ring with a little grease and gently fit to injector taking great care to avoid damaging it (I rolled up a little bit of thin card and used this to slide the o-ring into place)
13- carefully fit a new copper washer - check you put it on the way the old one came off there is a small ridge on them
14- refit first injector (I smeared mine with a little grease to help them slide back into the hole without damaging the o-rings)
15- continue with the rest
16- replace the cam shaft and tighten it to the correct torque setting
17- adjust the tappets by screwing the bolt in as far as it will go (don't over tighten it) then turn it back exactly one turn (360°) hold bolt with screwdriver and tighten the lock nut to correct torque
18- when all tappets set and checked smear a little grease into the groove on the rocker cover and fit the gasket to the cover
19- carefully reposition the cover checking the gasket hasn't slipped
20- stick it all back together again in the reverse order to which you stripped it apart tightening everything to the correct torque settings as you go
Check your oil level and run the engine. If all is good keep checking your oil level for a few days to make sure there are no leaks.
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