How To Replace An Injector Seal The Easy Way

[@orckaso6513]

hy m8, how did you clean the engine....,?

[@Qwerty1235945]

Superb work there Leon, and saved the owner a fair few quid by not having to replace the injector.

[@bodgitandleggitgarage]

Thanks mate

[@dootsize]

hi if you take the cutting tool you use for resurfacing the head and just use it on its own to resurface the injector face aswell you will not need to use a file on it ,just turn the cutting head by hand on the injector and it will leave a flat clean surface just like you did with the head

[@bodgitandleggitgarage]

?

[@dootsize]

@@bodgitandleggitgarage hi take the part of the reaming tool the part that has an allen key in it of the bit that you turn down in the hole were the injector goes to clean the face were the injector seal goes,and just put this part of the tool over the injector and turn it a few times with your hand and it will clean up the face of the injector were the copper seal goes an that is that cleaned as well ,no need to use a file !

[@Jonodrew1286]

This actually works very well!! Have to employ this method at times

[@willcram8350]

@@Jonodrew1286 With due respect, it absolutely doesn't work at all! At least it didn't for me! While this method may CLEAN the injector seat, it won't allow you to CUT the injector seat in order to repair erosion damage. This exact same thought (to use the seat-reaming/cutting tool on the actual injector seat) occured to me when I also realised that the injector I'd removed had an eroded seat. I even applied cutting compound to the cutting tool, but due to the fact that the seat of the injector is made of much harder material than the aluminium injector seat/bore in the cylinder head, the tool had precisely zero effect on the injector's seat, at least when used by hand (as I did). What I eventually did was to make a jig out of a piece of 3x2" wood and a length of L-section aluminium extrusion. I screwed the aluminium to the wood and then drilled a 7.5mm hole through the face of the aluminum (and an inch into the wood underneath) before using emercy cloth to clean the aluminum face around the hole, thus creating a flat, clean, hard surface. I then took a piece of emery paper (320 grit), punched a hole in it with an office hole-punch and then placed the punched emery cloth, face-up, over the aluminium hole (obviously with the holes aligned!). I then inserted the injector nozzle into the hole. You can now twist the injector left and right, while it's held in place in the hole, thus allowing the emery paper to gently and uniformily remove material from the damaged injector seat. (Obviously you have to ensure that you hold the injector vertically, but it's easy to 'feel' when the injector seat is flat against the jig). Keep using fresh holes in the emery paper as you wear them out. Unfortunately for me, the erosion was too severe and I was unable to completely flatten out the damage, so I bought a remanufactured injector. For other readers though, this method will hopefully work.

[@andrewlace]

Is it preferable to use grease to stop aluminium filings getting into the cylinder? Just researching prior to doing the job myself.

[@johncollins8304]

Fabuloso! Real-time drama with a happy ending. So these reamers are for re-cutting the metal of the seat, not just the carbon. I managed to make a slight cut with a 1/4" wood chisel getting the washer out. I had thought better than just leaving it and putting in a fresh washer, but suffered the result. Didn't know these cutters existed. It's only one hole , and not deep, deep like yours. Put a thin bolt through a dowel (exactly the centre??) and glued emery paper on. Spun it slowly on a drill. Reduced the cut a bit, BUT the seat is no longer flat -- has taken on a slightly concave look, probably because the bolt wasn't perfectly centred, the dowel was slightly smaller diameter than the hole I didn't keep the drill perfectly vertical. I've got a pack of pink carburundum (?) disks on spindles that are a better fit, better than anything in my Dremel-type bits.I will see if I find a cutter (I presume it has to be flat cos the injector holding the nozzle is flat) that is the diameter of the injector. You've also relieved me about not needing to worry about the nozzle being too far down. So, big thank you for sharing!

[@yhshah21]

Seen all the videos now on how to do this and your video is definitely the best out of them all! 👍🏼👍🏼

[@judedavidson5453]

How did you clean it all off? Mine is that bad . I'd like to have seen some of that footage. Thanks for that great.

[@wesleyholmes4360]

Good job👍👍 , I've done a few of them black death jobs on mercs , what did you use to clean top of engine off ? Looks like it come up clean

[@gregcressey1791]

I was wondering that as well came up really really well

[@StupidBlokeStupidVideos]

Probably oven cleaner

[@bodgitandleggitgarage]

Thanks a lot mate just good old-fashioned hard work a little bit of engine degreaser screwdriver and a jet wash

[@chrisday4653]

Carb cleaner on a hot engine works very well to melt the black gunk. Have to be careful using oven cleaner on the plastic parts.

[@DamiensFandMadventures]

Hey mate I'm doing this on a 2011 1.9 vauxhall insignia so I use the 17x19 one on the seats too, my kit didn't come with the instructions thanks in advance for your help

[@jonny1943]

The first good video about this subject!

[@jonny1943]

I just bought a second hand Outlander 2.2 di-d and got myself a nasty suprise, got two injectors leaking and they are crazy stuck, this is a challenge indeed.

[@igniux]

Loved the way you put everything in this video🤣 Thomas the tank engine and steam engine conversion got me real good 🤣🤣

[@opelmantamechanic8438]

Half tighten the clamp then knock the injector down to spread the washer and help it seal. One light but firm tap on the body with a small hammer and punch should do it . Then torque it fully .Clamping force alone isn't always enough to seat the washer. Also those ones like to strip the clamp threads out if they have been chugging for ages. What did you do to get it so clean at first? I was well impressed.

[@bodgitandleggitgarage]

I've never done it that way myself more than one way to skin a cat BOOM

[@paulelscey2465]

I usually use a head bolt of a k series engine to get the fire washer out. never saw a washer that bad before. And I usually leave it soaking in brake cleaner it helps soften the black death up .what did you use to clean it up .

[@bodgitandleggitgarage]

I've often seen him this bad mate the copper washers don't last very long once they start leaking

[@Dave-in-France]

Fantastic video, I have a question please. On my wife's Diesel Mini I have diesel smell in the cabin and baked-on black crap around the base of one or two injectors and the top of the head. My question is, how did you clean up all that black crap off the head before you started taking the injectors out ?

[@johnosullivan8068]

What do you use to clean the black gunk off?

[@alanmagee81]

Thanks for this. Is it necessary to grease the injector body? You didn't show this being done. Cheers

[@gedman9527]

hi mate im doing same job on jeep cherokee liberty 2002 2.5 crd how do i know if its a flat or tappered seet i have to cut , got cutting tool like yours , are they norm 17mm / 19mm flat cutter ??

[@bodgitandleggitgarage]

Hi mate when you buy the cutting tool you will see in the instructions which one you have to use depending on your engine

[@elcapitan6605]

how did you get it so clean? how did you wash it?

[@DaniailSeánOSuileabhain]

Hi how did you wash it please & what with

[@borisinjac]

What did you wash it with to start , is it a pressure washer?

[@andyh9464]

I’ve been told the vivaro/ traffic are the worse to remove?

[@sdgelectronics]

Is there any concern about any bits dropping down into the combustion chamber?

[@Skandalos]

Use a bit grease on the cutting tool so the shavings stick on it.

[@bodgitandleggitgarage]

Hi mate absolutely no concern whatsoever a bit are very small most the bits stick onto the cutter and they will just go through and cours absolutely no problem whatsoever

[@bodgitandleggitgarage]

@@Skandalos 👍

[@mack1609]

Pretty cool. Good save filing down injector.

[@bodgitandleggitgarage]

Thanks 👍

[@sejo88]

Hi friend, have this problem first injector is leaking, didnt help to replace bosch seal because the head valve cover is demaged becasue someone tried to remove injector with big force, this resulting that high preassure demage the seal and start leaking, so what you think if I put there some bigger seal than usual bosch measure? Maybe put 2 seals ?

[@peteramberley9952]

Cheers leon im going to tackle this on my hyundai 2.2 crdi

[@duggy788]

i had the same problem with a ferguson 35, 4 cylinder i tried new washers etc nothing worked and i didn't have the tool to resurface so i tried ptfe tape and it worked to my surprise .

[@bodgitandleggitgarage]

🤯

[@audreymeschkuleit8352]

What chemical you use to clean Engine Injector area?

[@mathiasedvardsen1795]

what do you use to clean it out?

[@haywardsautomotive6156]

The right tool makes it so much easier and that is a great tool!

[@bodgitandleggitgarage]

yes mate thanks you

[@ashy1423]

Great job Leon👍looking forward to loads of videos. Stay well Ash 🏴󠁧󠁢󠁳󠁣󠁴󠁿

[@bodgitandleggitgarage]

Thanks mate

[@ruffshayv4363]

Would cutting the seat mean using a thicker washer to keep the injector tip the correct distance into the cylinder?

[@bodgitandleggitgarage]

It just took a very very small amount of if you have to take too much off you're going to have to replace the head for certain engines you can get special thicker washers but not necessarily work very good all the time

[@lewis08peter]

What did you clean it with

[@barryging3512]

Beats an extension and a pry bar 😂😂 class tool that

[@bodgitandleggitgarage]

Lol

[@Naina-df2fr]

Am also facing this noise only in cold start what would be the reason ?

[@kevinhancock4064]

Fab video where can I get that kit from ? I strongly believe my cx5 has possible tired seals injector 1 was replaced bit be good to get other 3 seals done and check Injectors too chees

[@rosesbite]

Got this problem in cylinder 1 in my mk6 tdi 2.0. Thank you so much! Went to a few mechanics and they didn't know what the leak was coming from. Hopefully I can find a place to rent the tools to do this myself. many thanks from California! Also did you replace all of those gaskets in the same go?

[@JayMaverick]

Such a common (and simple) issue and a mechanic didn't know what the reason is? Shocking. Shameful that even with basic stuff like this the DIY approach is the most trustworthy one.

[@jayedmunds7525]

you put the injector back in, did you have to bleed fuel to the injector or just start it up once you’re all done.

[@harveysmith100]

Great video, thanks for that one Leon. I wonder what Mercedes would have quoted for that one!! You do introduce us mere mortals to some interesting tools. The seat cutter is exactly the same as a tap re-seating tool used by plumbers when people have left a leaky tap too long. Now before anyone gets excited and thinks they can use a £10 plumbers tool, you would never get it down that hole.

[@bodgitandleggitgarage]

Hi mate no it's not the same different heads have different shape cuts in them for the injector to seal properly it's not just a straight put in the injector different pitch for different cars

[@120poundsound2]

Hi, on the modern injectors if you remove one to do the seal do you have to recode them? I have a fiat 2.0 multijet. Thanks.

[@bodgitandleggitgarage]

hi mate you only have to recode them if you change them from different cylinders or if you change it from another vehicle only certain cars you have to recode

[@120poundsound2]

@@bodgitandleggitgarage thanks for the advice pal. Quite difficult to find info on a fiat diesel engine lol

[@bodgitandleggitgarage]

@@120poundsound2 anytime mates that's what these videos are all about I'm glad I can help

[@adriandukes7690]

Excellent and very in-depth video

[@bodgitandleggitgarage]

Thanks mate

[@piecetoyou8285]

I like clean and then vac most of the crud up be for cutting and a bit of grease on my cutter it helps all the bits of metal stick better to the cutter .then a rag taped on a rod with a bit of chemical to clean any left grease and carb, Probably a bit OTT but works well,

[@VikramSingh-ww1vn]

Wow that puller is awesome, saves time as no need to take apart the metering valve and stuff and screw in the puller from top... One question do we need to purge air out of of pipes before starting the car or like just plug in the injector and keep on cranking?

[@garybrown5500]

Just put the pipe & connector back. Common rail systems don't generally need bleeding at the high pressure side.

[@norfolkbushmanandfriends7916]

Hi, can you tell me what method you used to clean it all? i have to start on mine today & it's a hell of a mess. Thanks in advance

[@JS-ri2rx]

Great video many thanks. Keep up the good work

[@mikeberry304]

Lovely job there Leon , much easier using your nice removal tool than ripping out all the threads out of the injector , all that work for only a tenner including the new seal 😂😂😂💰💰💰💰

[@bodgitandleggitgarage]

If you know anybody that would do that for a tenner let me know and I will hire them

[@mikeberry304]

@@bodgitandleggitgarage so many customers think we should fix their cars for so little , it drives me mad , I just tell people who are like that that's how much it costs, if you don't wanna pay my costs , then take it away I've got plenty of other cars to fix

[@avezkhan82]

Hey brother 🙂 actually Sam problem may vehicle but not available this tool for me

[@mechanicmatt871]

That bendy bit in the injector puller is a great idea. Good job getting it to seal 👍

[@bodgitandleggitgarage]

Thanks mate

[@darrylirwin1399]

What did you use to clean it so well ?

[@arekgerwatowski5225]

to cut the face of the nut remove the cutter from the tool feed over the noozle and simply gently keep turning by fingers until surface its restored, best way, always work.

[@raymgoboziray4603]

Where can one buy the puller.

[@bodgitandleggitgarage]

Like I said in the video, the link is in the description.

[@johnwayne2638]

Is it only for cleaning the Seat or is it Also for removing the copper ring ? Imagine the copper ring dont come with the injector when you remove the injector,it Stays down.than you need to cut the copper ring with this tool or ?

[@madnadn]

Great job, Leon. Good informative video.

[@bodgitandleggitgarage]

Thanks mate

[@mrx1702]

Love the duct tape on the intercooler pipe

[@bodgitandleggitgarage]

🤣🤣🤣

[@paulroberts719]

Doing a black death job now on a mk 5 Mondeo it's been leaking for months as I had to chip away all the crystallised death, couldn't see the injector leak off pipe or wiring plug. I used celly thinners and acetone to help dissolve the crud, it works quite well at freeing it all off

[@bodgitandleggitgarage]

👍👍👍

[@martinpanks992]

My C220 did the exact same they are running the fuel pressures too high to get more power out of the notoriously slow Diesel engines something like 1200 bar! Which is phenomenal pressure and the seals don’t last very long at those pressures.

[@alanblack9540]

Great job done there Leon. Worked in Ssangyong for couple years and the 2.7 rexton and rodius had a 5 cyl merc engine. That was a regular on them. Bloody nightmare job!!! Especially cyl 5-the rearmost injector. Just wondering what you used to carry out the initial clean off? Came up great. The heater plugs was even better craic!!

[@bodgitandleggitgarage]

Yes mate I've worked on engines as well and they can be a nightmare the injectors love to see in them just good old-fashioned elbow grease jet wash screwdriver and degreaser

[@paulclifford4469]

Excellent video Leon

[@bodgitandleggitgarage]

Thanks mate

[@nissehult8565]

When replacing the injector notes bad problem with the seat (hole) is oval (half-moon) in the engine block (damage), skim toll is no option, tips for dealing with it? Do you have to replace the engine block or the entire engine (faster) or is there smart solution, find nothing when I search online. 😞 Does anyone know why it becomes the hole get oval under the Washer Seal/injector, it looks like the pressure has been blasting away material under high pressure for a long time. Even the Seal under the injector was oval = same size as the oval hole under = leaking. The hole towards the cylinder (lower part) looks circular, but the upper part to the top towards the gasket itself, is oval (half-moon) and on 50 lefts of the hole on the side it´s oval. but on the top side. The oval part is the size of half the material in the cylinder hole/gasket I did see in the video.

[@andymat7359]

What's your plan of attack with the jetwash to not fry electrics Leon? I've got a minging transit I need to get stuck into. Cheers

[@tommytouran]

ahh the good old black death done a sprinter a while back whole top of engine was about an inch thick with the crud had to replace the leak offs and the harness plugs as all broke off soon as i tried to remove them trouble was with its engine cover on you could not hear it chuffing but smelled like crap

[@bodgitandleggitgarage]

Lol

[@frankyates7910]

your vidios are great for learning and watching ...

[@bodgitandleggitgarage]

Thanks a lot mate

[@urbanjentry222]

Like it a lot won’t be cheap but it’s 1000% cheaper than removal and stripping of head

[@bodgitandleggitgarage]

Yes mate a lot cheaper than doing that for sure

[@CrimeVid]

Good job mate, I being bothered by stuff like this, would have made a narrow pipe end for my shop vac and cleared all that clart from round and down that ‘ole with the hope of getting the sealing washer out too ! What face of the injector did you file, won’t the hubikit do that too ?

[@bodgitandleggitgarage]

👍

[@JohnnysSpeedShop]

Good stuff mate...that injector puller looks pretty sweet...

[@bodgitandleggitgarage]

Thanks a lot mate yes it's awesome bit of kit

[@XyLoTec]

Use wd40 2-4 days before doing anything mybe IT will move. If the injector is stuck loosen the injector Bolt Run the engine give IT revs and the compression in the Camber will force IT Out. If you Font want debris to Fall Info the cylinder remove the glow Plug Blow Air trough that hole and Clean the Jacket Like you want or Put Vaseline on the Cutter all the debris will Stuck at the Vaseline Dont forget to use a thicker washer because the Standart wont Seal anymore

[@romanosautomotive]

Nice work. Those hubitools come in handy!

[@bodgitandleggitgarage]

Thanks a lot mate and yes very handy

[@Jonodrew1286]

Great instructional - think in 15 years mercedes would have considered sending out a bulletin on periodic injector washer maintenance service .... But then we’d be out of a job- I had to make a centralising bush for my cutting tool, as most on the market come without them - it would be so easy to be one -sided when cutting......as mentioned also, the cutter can also be applied to the injector nozzle nut, applying gentle pressure. As you quite rightly mentioned you can easily take a lot of material off, but also put radial striations on the seat which can act as blow paths. Keep up the good work👍👍👍

[@andy_v4443]

excellent work fella.

[@bodgitandleggitgarage]

Thanks mate

[@lukey3507]

What's with the duct tape all over the front hose?

[@bodgitandleggitgarage]

Obviously it's cracked and someone put that over it

[@johnfharvey]

Great video. Thanks. Wish I’d had that tool when I attempted this on my RAV 4. A nightmare!!!

[@bodgitandleggitgarage]

Thanks mate

[@fritsprive]

Very good and clear teaching video, thanks. Btw, why do people let this get soooooo bad, this steam engine conversion didn't happen overnight.....😱

[@bodgitandleggitgarage]

Thanks a lot mate your guess is as good as mine I do not understand some people either

[@arthurfricchione8119]

Boom sorted Leon another interesting one. What did you clean the engine with? Hope all ie good with you and family ❤️ Artie

[@bodgitandleggitgarage]

Thanks a lot mate just good old-fashioned elbow grease jetwash screwdriver and degreaser

[@theteadrinker-143]

Do they still call it The Black Death !

[@bodgitandleggitgarage]

Yes mate

[@rysacroft]

Some years ago I bought two refurbed Bosch injectors from a shop in Ireland. I've had no problems with them but I'm thinking that I may need to change the other two eventually. I've searched my emails but can't find any contact details, Gmail now seems to limit how far back in time is searchable. ISTR that the shop guy's name was Tommy, any ideas. P.S. I really enjoy your videos.

[@bodgitandleggitgarage]

thanks a lot mate in the perfect world it's always best to replace all of them at the same time but not everyone has the money to do it but like I said that's the perfect world and we don't live in the perfect world we live in the real world

[@mrbritcoinnakamoto2793]

should of used some grease on the tip of the seating tool to catch the shavings an you could of used the cutter to clean the injector tip by removing the center guide just a thought

[@matthewmcdonald8484]

Had the same problem with my e class ended up using the same tool to cut the injector as well as the seat.

[@bodgitandleggitgarage]

👍

[@BILLHOVER]

May be annealed the washer to make it more flexable would help to seat as well.

[@bodgitandleggitgarage]

?

[@BILLHOVER]

Like the old copper sump and spark plugs washer which could be reuser to seal tens of times. Try googling, annealing injector washers, may be opening a can of worms. but a good discussion point.

[@andrewallen9993]

IBM card punch sprig hook special tool from the 1950's ?⚒️

[@bodgitandleggitgarage]

Interesting send me a link and I'll buy one

[@andrewallen9993]

@@bodgitandleggitgarage A pleasure to return a favour. Your advice helped me out once I am happy to say 😁 christensen.co.za/category/219/service-aids Its the last item on the page and mine is now 30 years old.

[@bodgitandleggitgarage]

@@andrewallen9993 much appreciated thank you

[@BensWorkshop]

That must have been blowing by for a while to do all that damage.

[@bodgitandleggitgarage]

Yep lol

[@keithbranley6919]

Hoover always works if ya can seal around the top

[@bodgitandleggitgarage]

👍

[@orckaso6513]

tnx, gr8 video, loots of information

[@eddieMurphy11111]

I ha once on my old freelander and all the diesel and set and was solid it took me a day to get it out but all was good in the end its brought one thought to me who did I lend my cutting tool to .

[@bodgitandleggitgarage]

👍

[@paralleltripper]

Well done! 👏🏼👏🏼👏🏼

[@steves6577]

Just watched your video which is very good at explaining how to sort the 'black death' problem, but you made a bit of a mistake in filing the injector when you had the correct tool right there! Where you fitted the cutter at the shoulder of the tool with the grub screw for cutting the head, you can loosen and slid the cutter to the end (or use without handle) to recut the mating face of the injector, no filing needed.

[@time.528]

Boom!! Good awesome job

[@evzentikovsky3592]

but why this hapening? couse the injector bolts are loseing by vibretions and get lose and start leak...just every 5000km try the bolts if are tied

[@patkelly7999]

Good job Leon, that was blowing pretty bad:):)

[@bodgitandleggitgarage]

Thanks mate

[@spuriouspodge7416]

Leon, why do the seals go in the first place? heat and age? Thanks What did you clean it with btw? came up almost shiny

[@bodgitandleggitgarage]

Hi mate it'll be a lot of things heat and age would certainly be one of them also vibration of the engine it could have slightly come loose and cause issues as well

[@RichieRich845]

Oh $h!$ I get the same noise only when accelerate while driving, idle sounds fine. Thank for the video

[@RobBednarik-nd5lu]

Acetone literally melts that black goo off and then flashes away leaving no residue. Have to work quickly as it resolidifies.

[@maxthecaddy8451]

Great job mate Booooom 👌

[@bodgitandleggitgarage]

Thanks mate

[@burnyerbra7900]

Excellent!!!

[@125sm3]

Great job.

[@bodgitandleggitgarage]

Thanks mate

[@sliderdriver1]

I wouldn't recommend using compressed air and your hand to catch debris my friend. Could cause some injuries there😉

[@frugalprepper]

Never need to worry about that tool over here. I don't do Diesels

[@bodgitandleggitgarage]

Maybe you should expand and learn more things

[@frugalprepper]

@@bodgitandleggitgarage Nope, Diesels are dirty.

[@simonepusceddu44]

This is not an engine... This is thomas the train🤣🤣🤣

[@bodgitandleggitgarage]

lol

[@cesarjorgemurillobarientos1813]

good

[@sm7538]

The engines are annoying always have leaky injectors even after replacing the seals they let go again after another 20 to 40k miles

[@bodgitandleggitgarage]

The more they go the more I can fix them the circle never ends lol

[@lucaspamplonica]

Legend!

[@vinparaffin6082]

Easier than a Fiesta tdci !

[@lukey3507]

PSA crap, all the PSA Ford engines are junk. Siemens non serviceable injectors as well. Up until around 2008, I think they then used Bosch injectors if memory services me correctly. I won't own a Ford past 2002, they're cheaply made junk now.

[@sdgelectronics]

@@lukey3507 QNBA, Q4BA and similar engines are bulletproof

[@lukey3507]

@@sdgelectronics Engines might be bulletproof but nearly every single one of them has diesel pump failure.

[@sdgelectronics]

@@lukey3507 that's Bosch at fault then, but I don't believe that statistic. Certainly Alan Howatt has never mentioned this.

[@bodgitandleggitgarage]

The joys of motoring lol