OK, job done. It seems that I have repaired the leak, and the power has returned to where it was befoer all of this began. I filled the tank after the installation, so we shall see if the economy returns.
It took a bit of jiggling to get the injector out, but it was pretty easily accomplished. I found that gently using a small Snapon pry bar did the trick.
Oddly, there was no o-ring OR crush washer in there that I could find, only a bit of burnt up gasket-maker (I only hope that the PO did not 'fix' any other injectors). I spent about 2 hours cleaning the hole with solvent and bits of rag which I cut into 3" squares. I attached the bits of rag to a flexible grabber with the grasping hooks at the bottom. I could not see directly into the hole, so I used my phone to take photos of the hole (see attached) as I went along to ensure that I got the seats as clean as possible.
There was some minor pitting on the o-ring seat on the injector, so I cleaned that up with a bit of emmory cloth and then installed the o-ring and crush washer. The washer fits very snuggly and is made of a lovely soft copper, so it is apparent why it must be replaced each time. I then put a thin coat of motor oil on the o-ring to ease installation and gently worked it back into place. It was a bit tricky to get the chickenfoot back into place, but I found that taping it loosely to the injector before installing it (and then removing the tape once installed) worked well. To get the bolt in, I used a socket with a maget in it. Mind you, if it were any other injector (1-3), this would have been moot.
The popping noise is now gone, there does not appear to be any more exhaust leaking out the injector, and I am optimistic that it will hold up (touch wood). I will update if anything untoward happens.
While in the garage, I flushed the power steering fluid and replaced it with Amsoil Synthetic ATF and flushed the brakes. I also drained my BMW cyclonic filter and removed about 1/2 oz of oil.
I must say that after replacing the EGR and injector, I am more impressed than ever with this engine. While by no means as easy to work on as my Land Cruiser, it is remarkably easy to get to most things on the engine with a bit of creative thinking. I stand by my original thought, however, that this is a great engine wrapped in a Jeep.
I hope this helps anyone with a similar issue.
Cheers,
Chamba.[img][album][/album][/img]
_________________ 2006 Liberty CRD 4WD - BMW cyclonic filter, K & N air filter, GDE Eco Tune, Fumoto, Turbo Timer, full skids, steel roof rack and rails, obsessively maintained - Petrol is for pansies Assorted Land Cruisers 1986 BMW K100RS CU Alumni Flinders Law Alumni
Last edited by Chamba on Mon Jan 07, 2013 2:31 pm, edited 2 times in total.
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