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Old 05-06-2008, 05:46 PM   #1
abittenbinder
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Default Tech Alert-Perform this extra procedure at every oil change

I urge everyone to R+R their plastic valve cover at every oil change and inspect the injector compartment for any signs of leakage from the injector seat in the cylinder head. You can inspect the small diameter rubber fuel bypass hoses at the same time. You are looking for any abnormal deposits or discoloration around the injectors.

Removal for the inspection and the reinstallation is simple and fast. The bolts are 5mm ALLEN (NOT torx). The Pre '04 Sprinters have 8 securing the cover and the '04-'06 have 7 seven bolts.

If caught early you will simplify injector removal and safeguard your injector seat from further, more serious erosion.

Ignoring this condition will lead to possible breakage of the hold down bolt as well as severe exterior coking that may engulf the electrical connectors on the injectors and lead to a harness replacement as well as more time consuming injector extraction.

DO NOT allow someone to perform an emergency fix. I assure you, it will not last.

Kindly report what you find. And remember, YOU NO LONGER NEED TO REPLACE THE CYL HEAD. I can help. Doktor A

Last edited by Aqua Puttana; 08-27-2012 at 04:29 AM. Reason: OM647 seven bolts
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Old 05-06-2008, 06:29 PM   #2
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Default Re: Tech Alert-Perform this extra procedure at every oil change

Thanks Andy!

I will look by Friday pm.

Best,
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Old 05-06-2008, 08:26 PM   #3
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Default Re: Tech Alert-Perform this extra procedure at every oil change

What can be done to prevent this from happening ? Should the bolts be removed and anti siezed?
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Old 05-06-2008, 09:20 PM   #4
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Default Re: Tech Alert-Perform this extra procedure at every oil change

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Originally Posted by Aircraft Wrench View Post
Thanks Andy!

I will look by Friday pm.

Best,
Looking now is a good idea especially for those of you with significant miles who have never looked under there before. If you smell fuel/exhaust in the cab and/or have audible symptoms or erratic engine operation, inspect ASAP.

Those along my Pittsburgh to Florida route next week may wish to inspect and report any suspicious findings before my departure and return. Doktor A
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Old 05-06-2008, 11:54 PM   #5
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Default Re: Tech Alert-Perform this extra procedure at every oil change

Any pictures of where to look by chance. Im sorry to ask, but im a noob when it comes to engines and stuff

My van has about 68-72 thousand klicks on it, and ive never noticed any smells of fuel, tohugh as stated before, my engine/tranny makes a different sound sound like a vibrating sound close to 2000 rpm, and only just before 2000. After that, it goes away.
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Old 05-07-2008, 12:24 AM   #6
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Default Re: Tech Alert-Perform this extra procedure at every oil change

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my engine/tranny makes a different sound sound like a vibrating sound close to 2000 rpm, and only just before 2000. After that, it goes away.
Isn't that RSN?
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Old 05-07-2008, 12:19 PM   #7
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Default Re: Tech Alert-Perform this extra procedure at every oil change

I like Andy's suggestion to inspect under the plastic cover. The area underneath is the first place you will find any clue about impending failure of injector hold down bolts.

This Ladies and Gentlemen, is what you would hope not to find:
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File Type: jpg P1010006.jpg (156.0 KB, 4562 views)
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Old 05-07-2008, 12:36 PM   #8
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Default Re: Tech Alert-Perform this extra procedure at every oil change

Looking at the picture above, where would you say the leak is coming from?
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Old 05-07-2008, 12:50 PM   #9
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Default Re: Tech Alert-Perform this extra procedure at every oil change

Injectors one, two and three. Four and five were just beginning to protest - you can see this to the left around the hold down bolt at the base of number five injector.

Incredibly, it ran and performed satisfactorily.

What you can't easily determine from this angle is that the coke is upto two inches deep in places. It's a mixture of diesel and oil which has escaped past the injectors and solidified on the head. It stinks when you get close to it.

Last edited by mean_in_green; 05-07-2008 at 12:52 PM.
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Old 05-07-2008, 02:08 PM   #10
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Default Re: Tech Alert-Perform this extra procedure at every oil change

Quote:
Originally Posted by AzteK View Post
Any pictures of where to look by chance. Im sorry to ask, but im a noob when it comes to engines and stuff

My van has about 68-72 thousand klicks on it, and ive never noticed any smells of fuel, tohugh as stated before, my engine/tranny makes a different sound sound like a vibrating sound close to 2000 rpm, and only just before 2000. After that, it goes away.
MIG has just posted a (grim looking) photo of the injector gallery area. His photo clearly shows a WORST case of the hold down issue- endearing know as "the black death". But I must say I have seen even worse-a case were all the injectors were engulfed and no longer visible.

I do not want to alarm owners-this is NOT a widespread issue but it is a concern. Inspect this area NOW and keep an eye on it during every oil change or every second oil change- whatever is practical for you.

Owners in the Pennsylvania to Florida corridor-I encourage you to inspect this area ASAP and report any concerns to me-there is a chance I can visit during my upcoming road trip. Doktor A
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