Had a breakdown yesterday in my 1988 90 (19J), first thought was a head gasket as it was obviously not running on 4 cylinders, but there was no tell tale smoke at all. So, when pulled over, discovered No1 injector pipe was completely fractured at the injector end, diesel was everywhere, nice clean-up of the oils stains on the block though! Anyway, thought no problem, got a lift home and returned with old set of pipes that were replaced last year, popped it on and started it up. Still running on 3 cylinders and diesel pumping out of the union nut. Not as bad as the fracture but still loads. Took off the injector itself by the roadside and checked for obvious blockage but there was none visible and the washers were in tact. My question is can these simple injectors fail completely in a blocked position and therefore create enough back pressure to completely sever the injector pipe or is there another explanation. Waiting for the call to go collect a new injector, washer kit and pipe now so hopefully that will be the solution, but just curious if this is a recognisable issue, has anyone seen or heard of this before? Any help would be great, thanks

The pipes develop tiny pin holes usualy on the bends !! It may be due to a weakness in the bend !! Doubt the injector would cause this !!

youve most likely just got a bad seal between pipe and injector the flare gets damaged through over tightening over the years ,its running at 135 bar so needs to be good

So I have checked it all thoroughly today. Checked the pipe and it is fine, cleaned it off and wire wooled it at the olive. The diesel is literally pumping out of the injector / pipe union as if the injector itself is completely blocked or jammed. No diesel is getting through to the nozzle at all I took it all apart and it is very clean and the spindle moves freely. Put it back together and bled it through the return, but no luck. Does anyone know if these injectors will fail like this? Engine will not start now. Cheers Andy

try another injector on it ,the injector you took apart will need crack off pressure setting now ,cant remember ever seeing one causing that issue usually leak or have very poor spray

Thanks James I agree, never seen anything like this before. What else could cause total blockage like this? Waiting to get a new injector and pipe after the bank holiday shut down.

So, thanks guys you were right, it was indeed the pipe that was causing the leak. One fractured pipe and the old replacement was leaking so badly it was squirting out. Finally got a hold of some new replacements and all back to normal. Cost me the price of a new injector too, but all in a good cause. Many thanks for all your help, cheers Andy

andyham said:

So, thanks guys you were right, it was indeed the pipe that was causing the leak. One fractured pipe and the old replacement was leaking so badly it was squirting out. Finally got a hold of some new replacements and all back to normal. Cost me the price of a new injector too, but all in a good cause. Many thanks for all your help, cheers Andy

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how much did you pay for a new injector...was it a CAV recon ?