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Discussion Starter #1 (Edited)
Been reading more and more about this "Black Death" and from time to time I can smell fumes inside the cabin.

I decided, therefore, to check my injectors today.
Read all the threads and everyone says "Whip off the plastics ontop of the engine" or "Remove the plastics from on top of the engine" but the only photos I can find are AFTER the plastics have been removed.

I have removed all the bolts that I can see that hold the plastics on top, yet the thing is fixed solid ! Grabbing hold and shaking it simply shakes the entire van. Getting a small screwdriver between the upper and lower part forces it apart by about 1mm but that's it!
It's doing my head in. Are there any "hidden" bolts tucked away at the back of the engine or something?

This is what i am faced with, albeit the heavens have now opened so looks like I will have to continue tomorrow:





Is the inside of this pipe supposed to be all black and oily??



I am guessing this is the EGR pipe and thus supposed to be oily inside?



And I assume I am trying to get inside here for a good look around and check of the injectors:



Help !!!!!:crybaby2:

Paul
 

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As per Pictures..

Also take the inlet pipe off from the left!

Once this is off, Undo the 4 allen key bolts holding the plastic cover on hiding the Injectors. When you get to this stage you should see signs of BLack, Or if not then that ok! It could be the Sealing ring in the exhaust to Turbo pipe leaking fumes giving you the smell!!
 

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Discussion Starter #5
OK. I have done it......well i think I have.

Not sure if I need to remove the other plastic cover at the rear of the engine so if i do, please tell me ASAP as i wish to put it all back together again.
If I am looking at the right place, then am I correct is saying that everything looks OK? No sign of the black death??







This photo shows the rear plastic cover that I don't know if i am supposed to remove or not :confused:




Also, can some please let me know if these are supposed to be as coked up as they are? The van has done 147k miles if that helps.



Thanks everyone

Paul
 

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2000 Vito 110CDI (never should have sold it), Current project 1999 V220 Ambient
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I am sorry to say that the other plastic cover has to come off, the injectors are under it. It is held on by 6 or 8 allen bolts. I have a nasty feeling I can see carbon deposits oozing out from under it in your pictures.

I think what you are perhaps mixing up with the injectors are just the 4 fuel lines that run from the fuel rail, under the cover and into the top of the injectors.

The gunk in your mixing chamber that you can see is quite normal. I was horrified when I first saw mine and I went to a lot of effort cleaning it out. 6 months later I looked again and it was just the same
 

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Discussion Starter #7
OH MY F***ING GOD !!!!!!!!!!!!!!!!!!!!!!

I've had the van 2 weeks and I discover this :eek:





Is there realy an injector under all this??






Right everyone. What do I do next? I borrowed some money to help buy this van so to say I don't have hardly any funds is an understatement :(

I live in West Sussex just outside Chichester if anyone knows of anyone that covers this area.
From looking at the photos, does it look like I only have 1 leaking injector and it has been leaking for a bloody long time, or does it look like they are all leaking?

What am I talking price wise for a) to buy new injectors (4??) and b) to get someone to remove the old ones.

Am I right in saying that I shouldn't even attempt this myself and just leave it to the experts for fear of making a very bad situation even worse?

Sorry for all the questions everyone but to say I feel gutted and lost is an understatement.
:help::help::help:

Paul
 

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I was in the same situation about a month ago after buying my van at the end of October. I managed to get it all sorted myself although it took a while. I would definitely think your best off trying to clean up as much as you can yourself even if you leave reseating the injector/s to a pro.
What worked for me was a flat head screwdriver, an old vacuum cleaner, lots of paper towels and industrial quantities of carb cleaner.

You can see some photos of mine here
 

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Discussion Starter #9
Thanks for the reply.

I was thinking of getting some of this stuff here: http://www.uniteddiesel.co.uk/tips_docs/Turbo clean.pdf

So if I clean it up, would it be cheaper for me to remove the head and take it to a specialist somewhere (Can't drive the van now) and get them to remove and then refit a new injector?
Just thinking about costs you see and anything I can do myself will save me money as I fear injectors aren't cheap!

What are we talking price wise for an injector Vs a reconditioned injector?

Also, is it worth doing all 4 or just the one that seems to have the blow back which I am guessing is number 4 ??

Does anyone have any companys they recomend for refurbing injectors or supplying new ones??

Thanks

Paul
 

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Mate,

That looks horrible but don't dispair. A lot of V owners have been through this & there's a lot of advice available as a result.

Have search for 'Black Death' on this forum to get some hints on how to clean the coal off.

I'd also recommend you PM [email protected] I think he'll be able to see you alright regarding recon injectors, if you need them.
You should get away with just reseating them though, if you're careful about cleaning the gunk off them.

I think he does a mobile injector reseating service too, but you'll have to check that with him.

Good luck.

Regards,

Rob
 

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Discussion Starter #11
Cheers Rob.

Thanks for the advice. So I am guessing it is the little copper washer that gives way rather than the injectors themselves??

That would be great if that was the case and if I do in fact get the blowing injector out in one piece.
I think that is my greatest worry. Chipping all that crap off is a horrible job, but compared to if I snap the injector etc :eek:

Wish me luck. I shall be out there in the freezing cold snow working on it.

I'll fire a PM off to Mark also. :thumbsup:

Paul
 

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As already said, you will probably get away with new copper washers and stretch bolts.

Chip off and clean up all the mess, make sure nothing goes into the inlet maniold, put rags in! Then run the engine to get it up to operating temperature and carefully try and undo the clamp bolt holding the injector down, it may snap, they often do! Once that's out and the clamp is out of the way, undo the fuel pipe union from the injector and try twisting it out.

It's easier if it's warm.

Good luck and let us know how you get on :thumbsup:
 

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Discussion Starter #13
Is there a nack to removing the electrical connectors? They are welded on solid and so brittle that when I try and lift the lever that locks the plug in place, they all snapped instantly. In fact, number 3 was already broken and held on with a couple of cable ties from a previous bodge I assume.

Also, the pipe that runs across the top of all the injectors is so brittle, that with hardly any force whatsoever, this has also snapped !!

Can you buy replacement plugs and if so are they quite easy to replace? I just cant see how else I can get these off without prising them apart which will shatter the ever so brittle plastic.

Anyhow, back off into the snow to keep scraping etc.

Been using Surefex HD and am now about to use some Autosmart Tardis Tar remove to see if that helps!

Paul
 

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Discussion Starter #14 (Edited)
The 100% neat Tar remover seems to be doing a very good job of breaking it down. Could realy do with a small wire brush.
I am currently leaving it to soak for a while to give it time to work and for my fingers to defrost.

This is what I am currently faced with.



You can see the tie wrap on this plug.



These two plugs are now broken. What are the called?



This is the pipe that has a broken end. What is this called?



If people could tell me what parts I need to buy to replace these I would be very gratefull. Also, is there anything else I need to dismantle which might aid my cleaning or have I buggered things up too much already?

I am assuming that whilst the plugs will slide back in as a temp measure, with the broken pipe I wont be able to start it up to get the engine hot to attempt the removal?

Was thinking of this: Mercedes CDI Vito Injector Puller + Seat Tool HIRE on eBay (end time 05-Jan-11 13:03:29 GMT)

BTW, the tar remover is doing a cracking job at removing the coke !! I just don't have a way of sucking the bits of crap out as I don't think the other half would be happy to see her Dyson out in the snow sucking up engine crap.
 

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the pipe that runs across the top of the injectors is a leak-off pipe. the plugs would be called injector connector plug

edit. you could still run the engine with a broken leak-off pipe to warm it up. just be prepared to spill some diesel (try to collect it from where it leaks)

(the flash point of diesel is around 62 degrees centigrade. Below that it is pretty hard to set alight but take care if you do run it that it doesn't run on to a hot exhaust or anything hotter than 210 degrees c where it may auto ignite)
 

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Discussion Starter #16
Thanks for the info.

Not having any luck searching on Google for "Injector Leak Off Pipe" or "Injector Connector Plug".

Will just have to hope [email protected] replies to my PM and can also assist in getting these parts.

Would you advise I hire that tool from the ebay link before tackling the job?

Thanks again.

Paul
 

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forgot to mention I broke the clip on one of the electrical connectors as well but so far it's stayed on so I haven't replaced it.
 

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Its common to buy a Vito with leaking injectors , its a strange idea because this is a community of Vito owners, so why would you stitch up a potential new member of this forum. .

Don't worry it happened to me .

It was not freezing cold snow though. Are you doing it outside ?

Best advice is to see old threads on here and expect to put in a few hours of your time.

in this weather you will need to run it for 20 minutes to get it warm so best to sort fuel return first maybe . hotter helps get it out due to different metal expansion rates blah blah. wd40 wd40,soak , spray scrape, spray chip, soak, spray, etc etc

ps dont hire tool until you know you cant get it out . Mine came out quite easily. good luck.
and re; the broken do dah , put it back on run the engine what happens ? did you save the little clips that hold it on ?
 
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