1KZ-TE Injector install questions?

[tassie tiger Advanced Member Find all posts View Profile Close tassie tiger]

Hey

Put a set of new injectors in the Prado 120 today and came across an issue. The injectors were purchased from a well regarded diesel specialist.

I will try and attach two pics of what I am talking about but here goes;

When I pulled mine out there was a very small seal (washer) in the head where the base of the injector sits sealing the injector and the combustion chamber. There was a single washer with two small holes on the fuel return rail.

The new injectors had a small seal the same size as the one that mine had though it was a crush type seal. There was a new washer for the fuel rail and then another washer about 2.5mm thick made of brass or copper. I went over to the shop and spoke with the technician and he said that the crush seal was the first in like mine, then the brass washer and then the injector and finally the fuel rail washer. This didn't make sense as the brass would space it off the crush washer unless the new injector 'tip' was longer. The tech said "Thats how we do all the prados with denso injectors. Grabbed two spare crush spacers and headed home.

First up I set it up the way the tech said and torqued to 54nm. Put some blu on the injector to see if it marked from the crush seal. Pulled it out and the crush seal was unmarked. Put the crush seal back in but this time no brass washer and torqued to specs. Pulled it and the crush seal was crushed (hope the pic shows it).

So I installed them all without the brass washer and it ran fine.

Its been a while since I have been on the tools so started to second guess whether I got this right or not.

Thoughts?

[tassie tiger Advanced Member Find all posts View Profile Close tassie tiger]

So the pics worked. The first is the new injector with its seals/washers. The second shows the crush from torquing without the brass washer. It looks well crushed but in actual fact seems about right. Not too much and not too little.

[Pradonut Lurker Find all posts View Profile Close Pradonut]

I found the same first time I changed my injectors. It must be for a different head set-up.

[floatingkiwi Lurker Find all posts View Profile Close floatingkiwi]

Yeah just did mine, only needed the crush washer and the return rail Aluminium washers.

[david short Lurker Find all posts View Profile Close david short]

what about the injector seat, did you replace that also ??? the bit that sits in the head, I got those with mine also

[tassie tiger Advanced Member Find all posts View Profile Close tassie tiger]

HI David

If by seat you mean the squishable steel o'ring then yep.

[fridayman Senior Member Find all posts View Profile Close fridayman]

I'm about to recon mine, and I also ordered new seats (not squishable). How do I get the old seats out? I'm reluctant to try and hook them out in case it isn't that straight forward, and I then damage them trying. Or can I just hook them through the hole and pull?

[david short Lurker Find all posts View Profile Close david short]

no not the ring, theyre like a cup. they sit in the block. the ring goes between these and the injector nozzle I assume.
getting them out im thinking of screwing a srew into the hole n pulling them out

[david short Lurker Find all posts View Profile Close david short]

these suckers, the crush washers are there also

[david short Lurker Find all posts View Profile Close david short]

heres better views. I didn't get the copper washers with my injectors, theyre recons from hi tech here in sa

[fridayman Senior Member Find all posts View Profile Close fridayman]

Are you going to try first and then let me know how easy it was?

[david short Lurker Find all posts View Profile Close david short]

left em in there on the advice of a diesel mechanic mate. theyd be all carboned up n too hard to get out he told me. he was right. all good