If you're itching to keep going with it rather than waiting for the post, I have a set of E-Torx sockets that you're welcome to borrow.
 
I wonder if the number stamped on the injector is different to it's location because someone swapped them over to see if the fault moved cylinder, if they were thinking it was an injection problem. Process of elimination type thing.
 
No worries Andy.

I'm rather anxious to get the head off, to find out what has happened to it. In light of its recent timing belt, and refurbished/ new injectors, I'm thinking that it had this issue which someone was trying to fix. I'm pretty sure the inlet manifold is a second hand replacement, and it looks like the head has bee reconditioned recently. Maybe the reconditioned head has had an issue, maybe with a hydraulic tappet?
It's purely guessing at the moment, at least until I can get it apart to take a look.



I've just done mine left the rod out completely. So all the flaps are gone, and the rod is gone too.
I simply put the lever back in and refitted the clip.
This will keep the manifold air tight, but look original in the process. I've also left the vacuum motor disconnected at the moment, but it wouldn't make any difference if it was left disconnected or connected to the lever.
It's such a quick and easy fix, for what can cause serious damage to the engine.
View attachment 216095 View attachment 216096 View attachment 216097
I just need to fix said engine now.

Hi John.
Did you break up the flaps or was that how they came out ? mine came out whole and i cleaned them up just to see how much damage had been done to the ends which the rod passes through.

From this photo you can see the build up of gunk, not good at all.
hPhAhl8l.jpg
1

Manifold is in the barrel ready to be washed out.
cni8sljl.jpg
2

Removed the MAP sensor also to give that a good wipe over.
h42gBfdl.jpg
3

SB6RdT6l.jpg
4
 
Did you break up the flaps or was that how they came out ?

I broke them out. I couldn't be bothered to clean them, as they were going anyway. So I just twisted them to snap the plastic, and out they fell.

I'm going to give the inlet manifold a quick clean, but it's a job I'm not looking forward too. I'm still undecided if I'm going to blank the EGR or not.
 
If you're itching to keep going with it rather than waiting for the post, I have a set of E-Torx sockets that you're welcome to borrow.
Thanks for the offer, but the replacement E-Torx sockets will be here tomorrow, and I'm taking time off cars today. ;)

I'll get to it later in the week, after work.
I wonder if the number stamped on the injector is different to it's location because someone swapped them over to see if the fault moved cylinder, if they were thinking it was an injection problem. Process of elimination type thing.
That has crossed my mind too. I just seems very suspicious that all the injectors are new, and all were in the correct sequence, but starting at the wrong end of the engine. It makes me think that someone got the cylinder order wrong, which could mean the coding is also wrong.
 
Thanks for the offer, but the replacement E-Torx sockets will be here tomorrow, and I'm taking time off cars today. ;)

I'll get to it later in the week, after work.

That has crossed my mind too. I just seems very suspicious that all the injectors are new, and all were in the correct sequence, but starting at the wrong end of the engine. It makes me think that someone got the cylinder order wrong, which could mean the coding is also wrong.
It might be a bummer that the fault is so serious but it's a big result getting newly refurbed injectors. Gotta be worth around £600 alone. :)
It looks like someone spent a lot of dosh trying to sort this before giving up and trading it in or selling by auction.
 
It might be a bummer that the fault is so serious but it's a big result getting newly refurbed injectors. Gotta be worth around £600 alone. :)
It looks like someone spent a lot of dosh trying to sort this before giving up and trading it in or selling on Copart.

That's what I told the wife Ali. ;)

The most annoying part is she found a set of second hand injectors for £100 which I wouldn't have bought, had I known it already had a refurbished set.:mad:

From the top of the head all looks ok, but something is preventing that one valve from closing, but that'll wait till later in the week now.
 
You can sell them on and should only make a small loss on selling fees so no biggie. ;)
 
I broke them out. I couldn't be bothered to clean them, as they were going anyway. So I just twisted them to snap the plastic, and out they fell.

I'm going to give the inlet manifold a quick clean, but it's a job I'm not looking forward too. I'm still undecided if I'm going to blank the EGR or not.

Hi John.
I am just about to go out and jet wash the manifold clean, i blanked my EGR off as soon as i got it, in hope it will have kept the gunk down a little i will know once i change the manifold over for this clean one.
 
Re the injector numbering, they are back to front ( for me anyway) with #1 to the right, easy thing to mix up.
i always default to #1 at the pulleys
 
Hi John.
I am just about to go out and jet wash the manifold clean, i blanked my EGR off as soon as i got it, in hope it will have kept the gunk down a little i will know once i change the manifold over for this clean one.
I'll blank mine off, as soon as I assemble the engine.
Re the injector numbering, they are back to front ( for me anyway) with #1 to the right, easy thing to mix up.
i always default to #1 at the pulleys
Yes, the numbers are revised, compared to the standard numbering method, where No1 is at the cam drive engine of the engine, but on this Ford/PSA unit the cam drive end is No4.
 
Ok, so today I decided I'd remove the head with the wrong socket, rather than wait until the E-Torx. I figured that I'll be replacing the bolts anyway, so it doesn't matter if they get damaged by using a standard socket. I found that an 11mm hex fitted well enough to release the bolts, which is good enough for me.

However what I saw when I lifted the head wasn't what I was hoping for, it's ugly folks. :(

The problem was that No2 piston had obviously had the crap smacked out of it, :eek: but by what?
20200802_163212.jpg
20200802_163232.jpg


By this, which was sitting at the edge of the chamber in the piston crown.
20200802_163420.jpg
 
Ok, so today I decided I'd remove the head with the wrong socket, rather than wait until the E-Torx. I figured that I'll be replacing the bolts anyway, so it doesn't matter if they get damaged by using a standard socket. I found that an 11mm hex fitted well enough to release the bolts, which is good enough for me.

However what I saw when I lifted the head wasn't what I was hoping for, it's ugly folks. :(

The problem was that No2 piston had obviously had the crap smacked out of it, :eek: but by what? View attachment 216133View attachment 216134

By this, which was sitting at the edge of the chamber in the piston crown.View attachment 216135

This is like Time Team for Petrol Heads ... :eek:

I'll say 'it's ritual' ...:cool: could that be a valve stem cap or dint the Freelies have them ?
 

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