28-04-2012, 07:45 PM
Quick guide for changing injector leak off's. Some of this may apply to other models such as the NAD but this guide is aimed at the DT so adjust to suit.
Symptoms: Rough starting, Low on power, Smell of diesel, Slightly low economy.
Cause: Air getting in/fuel getting out.
Tools needed: 6mm allen key, 13mm socket, stanley knife Flat head screwdriver.
Parts needed: Fuel leak off hose (1m), End cap, d-seal.
First thing is to pop the bonnet and get the top mount out of the way, this is done by removing the 3 allen bolts along the back and if you still have them the 2 bolts at the front in each corner, I chucked these years ago as they are not essential.
![[Image: img20120428164059.jpg]](http://img338.imageshack.us/img338/7852/img20120428164059.jpg)
![[Image: img20120428164109.jpg]](http://img585.imageshack.us/img585/701/img20120428164109.jpg)
![[Image: img20120428164113.jpg]](http://img502.imageshack.us/img502/4215/img20120428164113.jpg)
You will also need to loosen the jubilee clip on the main boost hose and remove the small boost compensator hose from the bottom.
![[Image: img20120428164103.jpg]](http://img196.imageshack.us/img196/3342/img20120428164103.jpg)
Gently persuade the ic off and put somewhere safe. You will probably see diesel around one or more injectors at this point, mine had split completely on the pump side and had pissed diesel everywhere and also perished around the first injector. The rest were all completely dry but it is always good practice to replace the lot, especially as the stuff is so cheap.
![[Image: img20120428164420.jpg]](http://img688.imageshack.us/img688/4921/img20120428164420.jpg)
![[Image: img20120428164451.jpg]](http://img832.imageshack.us/img832/4229/img20120428164451.jpg)
You will now have access to the injector leak off pipes, they need to be removed one by one, I used each one as a template to cut from the new stuff. When removing them, if like mine and have never been replaced they may be fookin stiff, I used the stanley to cut a slit up from the bottom then worked them loose. After all of your new pipes are in bang on the end cap.
![[Image: img20120428165627.jpg]](http://img440.imageshack.us/img440/5872/img20120428165627.jpg)
You will now need to prime your diesel system and listen/check for leaks, if all ok replace the intercooler. A new d-seal should be used whenever the ic is removed from the engine to ensure there are no new boost leaks when it all goes back together.
Done.
Symptoms: Rough starting, Low on power, Smell of diesel, Slightly low economy.
Cause: Air getting in/fuel getting out.
Tools needed: 6mm allen key, 13mm socket, stanley knife Flat head screwdriver.
Parts needed: Fuel leak off hose (1m), End cap, d-seal.
First thing is to pop the bonnet and get the top mount out of the way, this is done by removing the 3 allen bolts along the back and if you still have them the 2 bolts at the front in each corner, I chucked these years ago as they are not essential.
You will also need to loosen the jubilee clip on the main boost hose and remove the small boost compensator hose from the bottom.
Gently persuade the ic off and put somewhere safe. You will probably see diesel around one or more injectors at this point, mine had split completely on the pump side and had pissed diesel everywhere and also perished around the first injector. The rest were all completely dry but it is always good practice to replace the lot, especially as the stuff is so cheap.
You will now have access to the injector leak off pipes, they need to be removed one by one, I used each one as a template to cut from the new stuff. When removing them, if like mine and have never been replaced they may be fookin stiff, I used the stanley to cut a slit up from the bottom then worked them loose. After all of your new pipes are in bang on the end cap.
You will now need to prime your diesel system and listen/check for leaks, if all ok replace the intercooler. A new d-seal should be used whenever the ic is removed from the engine to ensure there are no new boost leaks when it all goes back together.
Done.