2005 Vectra 1900 CDTi 150 Injector Leaking

[MXB74]

Greetings !

I have read the how too guide which was brilliant, however I still have some gas passing through the new washer.

I followed the how to guide to the letter, even had my dad (ex mech) watching over me, and everything was done ok, even dug out the torque wrench!

There is a groove on the injector body, looks like its a cut out for an O ring seal.....?

Or is the copper washer supposed to do all the work.....?

Any help welcome, thank you in advance

[4ndy]

The copper washer does all the work. I had a leak on injector number 1, 3 weeks ago on my car, which is the same as yours.

Less than 2 days later the leak was back and when I pulled the injector the 2nd time there was a mark on the copper washer that indicated a small fragment of carbon was still sitting in the seat, causing the seal to fail.

You need to be meticulous when cleaning the injector bore and the seat. The bore and seat needs to absolutely spotless.

A friend of mine who helped tremendously recommends fitting the copper washer with the curved side facing down, flat side facing the injector. It needs careful scrutiny to distinguish which side is which.

[MXB74]

Thanks for the reply!

I shall have another look but ran out of time today! The bore is pretty deep, how did you get them spotless?

When I pulled the injector out it was really manky, Not only did it take me ages to get the unit out, and a blister on my thumb, but ages to clean all the crap off the unit !

I reconise the curved side, and now cant remember how it went in!

Hopefully its no worse than it was, im too busy to look at it for the next 3 weeks, and we need to go away twice too !!

[4ndy]

I stuffed a very small rag down the bottom to prevent debris entering the chamber so that I could concentrate on the bulk of the bore.

I had a lot of careful scraping, wiping with rags soaked in petrol, soaking in rags drenched in petrol and then more careful scraping. Petrol is great for cleaning the bore because it evaporates.

My air compressor was very useful for periodic blowing out and then an old bicycle spoke to pick out all of the little bits around the bottom and recover the small rag before carefully placing the copper washer in the correct way round with it.

I would avoid leaving it too long. My number 1 was gone for a while and the escaping diesel ran into the number 2 bore welding that into place aswell!

That only manifested itself as an issue when number 3 started leaking and number 2 had to be removed in order to release number 3!

[MXB74]

My number one is the problem, and i think its been going on long enough to weld in number 3 !!!!!!! (I have known about it for a while)

The joys of a nice plastic cover over the top of the engine eh!

****** cars, just replaced the alternator too