300Tdi Defender
FUEL SYSTEM
3
REPAIR
FUEL INJECTORS
Service repair no - 19.60.10
Remove
NOTE: When a fuel injector is considered
to be the cause of irregular running and
loss of power it will be necessary to fit a
donor set of injectors to determine which injector
is at fault. DO NOT attempt to dismantle or carry
out spray tests on the fuel injectors. This work
can only carried out by authorised Bosch dealers.
1. Remove oil filler cap and release sound
insulation cover from top of engine.
2. Disconnect high pressure fuel supply pipes from
injectors and injection pump. Remove in pairs.
3. Disconnect spill return hose(s) from injectors.
4. Plug pipes and injector connections to prevent
the ingress of dirt and foriegn matter.
5. Remove retaining nut and release each injector
clamp plate from cylinder head.
6. Remove injector and discard copper washer.
Refit
7. Ensure injectors and seating in cylinder head are
clean.
8. Lightly grease a new copper sealing washer and
position on each injector.
9. Fit injectors in cylinder head with spill return
outlets facing outward.
10. Secure injector with clamp plate and nut. Tighten
nut to
25 Nm (18 lbf/ft).
NOTE: The clamp plates are slightly
curved and should be fitted with the
convex side uppermost.
11. Fit the spill return pipe with a single copper
washer under the head of the banjo bolt and 2
copper washers fitted between the injector and
the banjo. Tighten banjo bolt to
10 Nm (7 lbf/ft).
12. Fit high pressure pipes to injectors and injection
pump. Tighten union nuts to
28 Nm (21 lbf/ft).
13. Fit sound insulation cover and oil filler cap.