Volvo S60 D5 Injector issue

[bigstraight6]

I think I have a fuel injector issue, I’ve noticed a kerosene like smell from the drivers side bonnet area in the last few weeks and this evening I could detect a slight chuffing noise.

I whipped the engine cover off and said chuffing noise is much more noticeable and there’s an oily deposit at the base of the injector where it enters the cylinder head, and yes it’s the injector on the far right of the engine.

So I’m guessing that’s the problem, anyone on here changed injectors on one of these?

[Wingz123]

Sounds like a seal needs changing to me not the injector itself. Get it done sooner rather than later for fear of black death and then it being mega stuck in the head.

 

Black death is carbon deposit that leaks around the injector seal and essentially glues the injector in place. I had the injector seals changed recently on my Mercedes Sprinter - they are notorious for injector seals going. I had it done two days later and the injectors came out no problem.

 

If I were you, I’d have all 5 changed. D5 engines are common for injector seals going too

[Broadsword]

Haven’t had to tackle such a job on a D5 but it sound like the injector seal is leaking. Probably best to tackle it ASAP as in that case or all the carbon build up will have the injector stuck in the bore. Some Mercedes CDI engine is very well know for such an issue. Injector seals cost pennies.

[Broadsword]

Hah, Wingz just beat me to it while I was writing basically the same reply.

[Wingz123]

Here is an example of where the injector seal leak has been ignored....good luck getting those injectors out...he/she should have got straight on to it as soon as he heard the first slight chuffing

 

DO NOT LEAVE IT! And I would advise changing all 5 on yours at the same time for peace of mind, not just the chuffing one as you know you’ll get it back together and the week after next another one’ll be developing that choo choo noise!

 

The picture below is from a 2006 Mercedes Sprinter

[Wingz123]

Here is a how-to guide....easy on a d5 access is nice...

 

[Dead_E23]

I've done it on a D5.  I don't remember the injectors being particularly difficult to get out, although one or two were a bit stiff and I think i gave them a bit of a wiggle with a big adjustable spanner.  I do remember being worried about it though, and there are videos on YouTube of people using slide hammers and so on.

 

Be careful with the pipes, as I believe they're a bit brittle and you can knacker the ends by overtigtening them.  Similarly, the tiny bolts that hold the clamps down only require the gentlest nipping up.

[Zelandeth]

Here is an example of where the injector seal leak has been ignored....good luck getting those injectors out...he/she should have got straight on to it as soon as he heard the first slight chuffing

 

The picture below is from a 2006 Mercedes Sprinter

Bloody hell that's an impressive one!

[beko1987]

That's exactly what happened to my 2.2dci laguna! Pissed oil out of the rocker cover gasket (shared with the exhaust manifold so a £££ item), and blew to the point that on a cold morning you could see it out of the 2nd injector. Scrapped it a few months later..

 

Do it now whilst it's an easy job! Or run away like I did

[ruffgeezer]

D5 is a fairly easy one. Only disturb what you need to.

 

I had to replace one injector as it was leaking back excessively meaning it wouldn't start. I has it done in half hour iirc.

[beko1987]

D5 is a fairly easy one. Only disturb what you need to.

 

I had to replace one injector as it was leaking back excessively meaning it wouldn't start. I has it done in half hour iirc.

Yes but u r a mechanic... I'd shit myself and loose a weekend trying it!

[ruffgeezer]

Well I Am, that is true. The access on the d5 is great, the worst bit is wiggling the injector free.

 

I think I might have loosened the clamp on mine and run the engine up until it «popped" out. Of course with the seal failed, it might not be necessary.

[Minimad5]

I've got a set of 4 (as used one on my V70) .. Injector mounting kit, which is everything you need to do the job.

Throw us a P.M if you want to buy the lot (got some other bits too if you're interested)

[pauldoubleyou]

Also had this on a Vito but caught it early. Dead common, usually nothing more than some copper washers and bolts. 

 

I was quite busy on the vito forums at the time (638) and i started doing kits on ebay for a fiver. Sold loads, cost pennies. 

[forddeliveryboy]

I'd also only touch what needs doing, the one injector which had a leaky seat sorted on the V70 started to fail soon after it'd been out which isn't uncommon.

 

That was 40k ago, none of the others has started leaking since.

[garbaldy]

Yeah don't wait do it straight away as soon as you hear the chuffing.

The spaceship I did was an absolute ball

ache and I was on the verge of throwing in the towel which is not like me, the carbon build up took some shifting and I tried everything in my arsenal to remove it but in the end it was a scrape job.

[bigstraight6]

Many thanks for the replies and advice, I popped down to Euro Car Parts earlier and got the new copper washer, the injector came out with a bit of persuasion with a set of grips. The copper washer on the end was very thin compared to the new one, cleaned up the injector and scraped the foul smelling bituminous mess from around the injector hole and bunged it back together.

The difference in the car is very noticeable, and sounds great and is pulling like a train now.

[Wingz123]

Fantastic! Well done - glad you got it sorted. Glad access is pretty good on these too.