By jcw on Thursday, June 21, 2001 - 04:00 am: Edit

I've tried to get info on changing fuel injectors on this board, another board, and a mailing list. Also searched the web. Nothing. Hasn't anyone changed injectors on their Disco?
Questions...
1. Does the plenum have to be removed, or can the fuel rail be removed without doing that?
2. Can the injectors be removed individually without removing the fuel rail?
3. Tips/tricks/traps?

Thanks.
John
jixix@aol.com

By Kyle Van Tassel (Kyle) on Thursday, June 21, 2001 - 04:14 am: Edit

Typically the upper plenum has to be removed so you can get in there and work. nce thats off its pretty straight forward. Have you removed injectors before on anything?

Kyle

By Jon Williams (Jonw) on Thursday, June 21, 2001 - 04:27 am: Edit

Upper plenum off, fuel rail off, then you can simply pull the injector(s) out. You'll need new o-rings for the injector (and don't try to reuse them, as you'll have a leak worse than you did before). You'll need to releive the fuel system pressure before you do anything. I don't know off-hand how Rover recommends, but other vehicles I've worked on (foreign and domestic) the procedure is pretty much remove the gas cap, unplug the fuel pump fuse, and start and run the engine until it stalls. But vehicles I've worked on, the engine never started, so I just cranked it for a good 5 seconds or so. Then do all your work on the fuel rail etc., plug the fuse back in, put the gas cap on, and crank the engine 'till it starts (maybe 5-10 seconds?). That's about all there is to it.

By wisker on Thursday, June 21, 2001 - 05:28 am: Edit

RPI has injectors as well as some fancy aftermarket fuel pressure regulator. Check their website.

wisker

By tms ltd on Thursday, June 21, 2001 - 04:46 pm: Edit

Its basically as simple as Kyle says and i would like to add something to the restart procedure. The ecm will shut off the fuel pump after only a few seconds of running. In order to reactivate the fuel pump after the ecm cuts off power, you may need to turn the ignition off for 15 seconds(or until you hear the relay drop out.) you should do this routine maybe two or three times, check for leaks now that the system is pressurised, (fix any leaks) then start the engine.

By jcw on Friday, June 22, 2001 - 02:27 am: Edit

Thanks for all the info, folks. Couple more questions...
1. If I'm just changing one injector, I should probably still replace the lower o-rings on the other ones too, since they'll have to be pulled from the manifold when the rail is removed, right?

2. Are these ordinary o-rings that can be gotten at a good hardware store, or something special?

3. Is it necessary to disconnect the fuel lines from the rail? Seems like the flex rubber tubing connections would allow just lifting it...then a quick pressurization would show the leak state of all the injectors (with proper fire precautions, drip tray etc).

Thanks again.
John

By Jon Williams (Jonw) on Friday, June 22, 2001 - 04:19 am: Edit

John,

Personally, I would replace the o-rings on all the injectors, since some will pull out of the manifold and some will pull out of the rail. Either way, the original seal will be broken. However, you're not required to replace them. But since a bag of injector o-rings for a V8 is about $2.99, it's a small price to pay.

I've never seen them at a hardware store, but an autoparts store is where to buy. I don't know who sells the right o-rings for Rover engines; maybe NAPA? Or maybe somewhere online? Anyway, they're not all universal, but other vehicles that use the same injectors as a Rover engine may be easier to find. One way to do that is get the part number from the injector and see what other vehicles use it, then you'll have no problem locating o-rings. Of course, there's always the dealer, which will probably sell you o-rings at $2.99 each...

Don't know about the fuel lines. I would think the culprit injector would be obvious, since gas leaking on an injector will form a brown varnish from the heat. Most of the time, injectors fail internally and the leaking gas kinda oozes out as the injector is operating. But if you think it may not be an injector and only a seal, then the test you described is a good idea.

By jcw on Wednesday, June 27, 2001 - 06:25 am: Edit

I've ordered 2 injectors, and can return one if I don't use it (may find another leaky one?).

Believe it or not, LR price (through a discount supplier even) is $3 - $4 PER O-ring!!! Well, I've ordered some of them since I don't know if generic ones would work...but could return them...anybody know if other "standard" V8 injector o-rings will work, for certain, on the Disco injectors? There are two part numbers listed, upper and lower, with different prices. Any info appreciated.

John

By Jon Williams (Jonw) on Wednesday, June 27, 2001 - 08:31 am: Edit

Yeah, I was picking through a Bosch fuel system parts manual just because you got me thinking and I saw the two o-rings required. It's a Bosch injector, and I was able to find a couple other vehicles that use the same ones, but they required different seals. And unfortunately, the o-rings were expensive and differently priced for each. Sorry to get your hopes up.

By jcw on Wednesday, June 27, 2001 - 04:34 pm: Edit

Jon...
Could you give me the Bosch part number? I'd like to investigate other possible sources for injectors. If they're Bosch, maybe NAPA or other parts chains could order them.]

Thanks.

John