Technical 02-06 2.8 jtd injector seals/washer

[JennyV]

Hello,
This is my first post on the forum. I'm just wondering if anyone can help me out with the injector seals for my 06 ducato 2.8jtd van? I've got a leaky injector that leaks oil and upon pulling it out, I cannot see any seals around the top or in the hole. All I see are built up carbon which I cleaned out. It's my understanding there should be a copper washer there, but there isn't, and I can't seem to find a part online for it. The injector is a Bosch 0445120002. What I've done instead is put a regular 1/4" washer down the hole and tightened it back up. I haven't started her up yet, but does anyone know if what I've done is correct or if there should be a specific washer for it or are these models just don't use washers??

Thanks, jenny

 

[JennyV]

Hello,
This is my first post on the forum. I'm just wondering if anyone can help me out with the injector seals for my 06 ducato 2.8jtd van? I've got a leaky injector that leaks oil and upon pulling it out, I cannot see any seals around the top or in the hole. All I see are built up carbon which I cleaned out. It's my understanding there should be a copper washer there, but there isn't, and I can't seem to find a part online for it. The injector is a Bosch 0445120002. What I've done instead is put a regular 1/4" washer down the hole and tightened it back up. I haven't started her up yet, but does anyone know if what I've done is correct or if there should be a specific washer for it or are these models just don't use washers??

Thanks, jenny

Oh and I've looked in elearn manual could not find anything on it. I also could not find a torque spec for the 'fixing bolt' for the injectors ..

 

[Communicator]

I have not had to remove an injector from my 2.8jtd, but I also would expect to find a copper washer. I trust that the washer fitted was indeed a copper washer.

While eLearn does not specifically quote a torque for the 2.8jtd, it mentions 2. 5dNm, (25Nm) and then restricts this to the 2.3jtd. I suspect that this is an error of omission.

 

[bugsymike]

As @Communicator says.
It should have a new copper sealing washer, if you identify the Bosch injector it is used in many other makes of vehicle, even Fords,so you should be able to get the correct copper washers. I would not leave the steel washer in there.
Over here they are listed on eBay etc. but I have had good service from Darwen Diesels UK (sorry not Australia)

 

[JennyV]

I have not had to remove an injector from my 2.8jtd, but I also would expect to find a copper washer. I trust that the washer fitted was indeed a copper washer.

While eLearn does not specifically quote a torque for the 2.8jtd, it mentions 2. 5dNm, (25Nm) and then restricts this to the 2.3jtd. I suspect that this is an error of omission.

Yes the 1/4" washer is a copper washer, just not a injector specific one.
Surely it'd be more than 25nm, the fuel pipe flare nuts are 26-32nm. If I'd take a guess, it felt more like 40-50nm to undo.

 

[bugsymike]

Is this any good, sorry for shakey hand photo, old age, not alcohol honest.

 

[JennyV]

Is this any good, sorry for shakey hand photo, old age, not alcohol honest.

Oh wow thanks! That's some invaluable specs for it! But still quite surprised injector clamp is only 26-32nm.

 

[Communicator]

Yes the 1/4" washer is a copper washer, just not a injector specific one.
Surely it'd be more than 25nm, the fuel pipe flare nuts are 26-32nm. If I'd take a guess, it felt more like 40-50nm to undo.

While @bugsymike was taking photographs, I was checking on the internet. Assuming an M8 bolt 8.2 grade steel, the answer was 25Nm. The page that I used also cautioned that the figures given were for dry unlubricated bolts. I would be reluctant to go higher than 25Nm.

If you have not already fitted the injector, you could consider annealing the washer. Given that inner and outer diameters are OK., the only other variable is thickness.

 

[JennyV]

While @bugsymike was taking photographs, I was checking on the internet. Assuming an M8 bolt 8.2 grade steel, the answer was 25Nm. The page that I used also cautioned that the figures given were for dry unlubricated bolts. I would be reluctant to go higher than 25Nm.

If you have not already fitted the injector, you could consider annealing the washer. Given that inner and outer diameters are OK., the only other variable is thickness.

Thanks @Communicator, yes I'd say 25nm or the 26-32nm would be the correct torque spec.
Also I made the mistake of saying I used a 1/4" washer, but infact I used a 5/16" copper washer. Regardless, I've since started the engine and it seems to be working fine, can't quite take it for a test drive as I'm waiting for a replacement clutch.

Interestingly, I believe the correct part I would need are the F00V C17 503 with a thickness at 1.5mm, although since I used a 5/16" copper washer at 0.9-1mm thick, it conforms well between the curved mating surface down the hole and on the injector. Bosch does selll F00V C17 504 or 505 parts with a respective 2mm and 2.5mm thicknesses, but given it had no washers previously and it needs to form a curve, I'd be reluctant to use the thicker ones. Although like you said, annealing would make it softer and conform better.

 

[Communicator]

Thanks @JennyV , I have saved that Bosch part number for possible future reference.
I did say assuming M8 bolts for injector clamp, but my memory may be wrong. When checking that I had saved correctly to pdf, I discovered some previously saved relevant information that I had forgotten, pages of torque settings for the Iveco Daily 2.8jtd, which is basically the same engine, but with a different bottom end.
Pages attached below. Injector bolt is listed as M10 x 1.5 hex (cap screw?) Torque quoted is 40Nm.