Blow from Injector (with pics)

[Monocle]

I was nearly home after a three hour driver this morning and noticed a strong smell (like burning rubber) in the car (IS220D). 

When I pulled into the driveway I took a look at the engine with it running. There was a blowing sound which I quickly saw was coming from one the injectors. It also looks like some sort of rubber or plastic been spit out with the blow. It looks like oil spray but it is hard. See pics below. There was no smoke and the smell was not diesel or oil. 

The blue arrow just indicates the direction of the blow out. It is coming from the back (not visible side of the port). 

The schematic of the engine block refers to this part of the injector as the nozzle leakage assembly. I have no idea what this is.

 

I have a feeling that a rubber gasket has failed and is being melted away by the heat and pressure. The red circle is where the problem is and the blue is my best guess of what has failed. 

 

My question is, has anyone encountered this problem? Also, I want to pull it apart to see exactly what went wrong, but I don't like pulling out injectors. 

Thanks

[madasahatter]

There is a how to on the forum possible blown injector.

[madasahatter]

2 minutes ago, madasahatter said:

There is a how to on the forum possible blown injector.

Also just seen this may be of help.

https://www.clublexus.com/forums/is-2nd-gen-2006-2013/652048-is-220d-injector-replacement.html

[Monocle]

Thanks madasahater. I can't see the how to guide but I have ordered the seals (arrive Monday) and I'm going to give it a go myself. 

I think I have caught it very early so I am hoping the copper seal isn't too stuck! I have seen some failures and the build up is significant - I only see a small amount on mine. 

If you can find that how to guide, please let me know. Otherwise I will do one up if I'm successful!

[Monocle]

I just took out the injector there. It was a straight forward job. Took about 45 minutes total - 15 of which were spent trying to get the copper washer (seal) out. 

You can see the damage to the copper washer below (two notches) and the o-ring half way up the injector. Also included is a pic of the injector itself. It was a bit stuck due to the build up.

Parts are arriving on Monday so will fit and do full DIY Guide then. 

[Farqui]

Well done, working on injectors can be tricky. But it looks like you're over the worse of it now. Fingers crossed that it all goes back together smoothly.

[chr15gb]

Always good to see someone getting their hands dirty rather than throw cash at a garage.  Hope it all goes well. 

[Monocle]

Job done - will do How To Guide soon. 

Honestly, a very easy job. However, I think the fact that I caught it early meant the washer was reasonably free and the injector itself didn't need too much effort to pull out - so I got lucky. If left for longer, that black gunk would probably build up more and more and make it difficult to get both out. 

The parts were €7 for the copper washer (not copper anymore!) and the o-ring (which isn't a perfect fit unfortunately - it is the right diameter but the thickness isn't the same as previous). Total job time is about 1 hour (minus trip to collect parts!).

Also, on doing some reading on this forum about getting the washer out, there are concerns about the washer falling into the cylinder chamber below. I'm not sure how this is possible unless the washer had split. But if it is in one piece, it cannot physically fit down into the cylinder. So, I think the risk is very low. 

Highly recommend doing this job from a satisfaction and financial perspective. I was tempted to do all four at once but I have read that they should be left well alone until a problem occurs. Not sure I understand why fully - I know the injectors are sensitive pieces of kit but as long as you are careful, it shouldn't be a problem. I'd welcome some opinions on this. 

 

How to Guide: 

 

[Farqui]

I don't think injectors are a good item to regularly remove as they can become stuck in position (more so on diseasels) and then need a specialist puller to remove them. Worse case they can break which then makes the job x times more expensive.  So follow the mantra, if it ain't broke then don't fix it.

[chr15gb]

In my old BMW 530D days we used to use this video as a good example of what it can be like removing a stuck injector lol

 

[Farqui]

[Monocle]

Thanks Lee and Chris. Well I think it is safe to say that I got very lucky! My god that is horrendous and scary!

[Shahpor]

Nice one.  Always handy to have a guide if the need arises.

Yeah, if you guys ever read Practical Performance Car magazine a couple of years ago, the Editor Will had a BMW 530D, and even using the method linked above the injector just wouldn't come out.  It was almost like it was welded in!

[Monocle]

I was about to head off for a week long driving holiday when a second injector was blowing. That makes two within the space of 1500 miles! Bit frustrating but very lucky that I bought spare seals when the first one went. 

The washer was a bit more stuck than the last one. The injector came out ok but the washer took about 20 minutes.

One thing I did learn (the hard way) was not to do this repair job with the engine hot. The fuel return line is very easy to bend when hot. So much so that when I was loosening the bolts, the line would twist and bend. It didn't break however but it could have been a disaster.

Seriously considering doing the remaining two at this stage!