d5 injectors

[noscralc]

Bit of fun i had yesterday changing injectors which may be of interest.
Noticed for a while car (2003-v70 d5) had been lumpy on first starting up-getting progressively worse but seemed smoother when hot-no starting problems either and pulled well so decided to do a leak test using a cheap kit off ebay-which by the way worked a treat once i got the proper adaptors on the drain pipes,anyway it showed No1 counting L-R and No3 were leaking quite a bit more than the other 3 so set about changing them using 2 so called good ones off ebay.
Starting with
No1- i fell at the first hurdle the LH torx screw rounded off but fortunately it was the one nearest the timing cover so was able to get at it with a thin chisel and tap it round-the other one came out fine needless to say the screws are rubbish if they have been over tightened so replaced them with m6 cap screws.
No3 came undone no problem and as i had no more cap screws replaced the originals.
Now there is a lot of talk about fitting kits/pipes which in my opinion are a unnecessary expense as the replacement injectors were complete and if you are careful no disturbance of the pipes-but i did fit new copper washers to the bottom of the injectors.
Car now seems much quieter and smoother than before so happy days.
I shall be sourcing more cap screws because if it had been one of the inner ones rounded it would have been a different ball game--why o why do volvo insist on these horrible torx screws cap screws (allan studs ) much better.

[cheshired5]

Originally Posted by noscralc

Now there is a lot of talk about fitting kits/pipes which in my opinion are a unnecessary expense

Pipes I'd agree with but fitting kits come with new clamps which have a pronounced bend in them to give a spring clamping force at the correct bolt torque.
If you don't bend the old clamps carefully to resemble new, you have to achieve the correct clamping force with tighter bolts.
The kit also comes with new bolts

It sounds like over tightening is what's happened previously and why you struggled with rounded heads.

[Bashy]

I reused the existing kit and failed miserably, it leaked and produced injector knock, I quickly ordered the kit that took 10 days to arrive (don't ask), once fitted, all was well in that respect, my Kit came with the clamp and bolts, others come with o-rings, depends on the car I think, Euro 3 has 0-rings I believe...

I am yet to attempt another leak back test, been putting it off since the 1st try failed spewing fuel out of the return pipe :/ been told on here to clamp it off, need to figure out what to use as a clamp mind hence putting the test off, it wasn't easy mopping up diesel from the rocker cover