AdBlock Warning

Parts of this website do not function properly with AdBlock enabled on your device. To get the best user experience on our website, please disable Adblock for this website (domain) on your browser.

Injector Seal Replacement - IS220D


How to replace the bottom seal on an injector when the injector is blowing (spitting black plastic-like material is a sign)

Job time – 1 hour 10 mins

Disassembly (40 mins) - may take longer if in a bad way

Cleaning (20 mins)

Reassembly (10 mins)

Tools required: Socket set 10mm, 12mm, 14mm and 14mm spanner. Also need flat head screw driver for scraping and some WD40. Lots of rags/tissue paper. Wire coat hanger or similar strength wire and cutters. Vacuum cleaner.

Parts: Copper washer (injector seal) and O-Ring (half way down the injector). Part numbers: 11176-51010 and 96721-19017 respectively. This is for a 2007 IS220D.

I reckon I saved about €400 (£340) by doing this myself (from the prices I have seen on this forum).



Remove wire harness clips (2) on wire harness that runs over the injectors. Both broke on me as they were fragile from heat over the years. Didn't bother replacing

Remove wire harness nuts (2) 10mm socket

Disconnect all four injectors' electrical connections (don't worry about mixing them up, they can only reach their own injector)

Lift wire harness up a little and move to the left out of the way


Disconnect Fuel Leakage Manifold Pipe. See red arrow above. This is a flexible hose that is clamped onto a solid inner pipe (I have a feeling this may not be necessary - I'll check and edit)

Remove bolt (1) 10mm securing one of the fuel lines. See yellow arrow above

Remove back bolt (1) 14mm on back on the Fuel Leakage Manifold. See blue arrow above. This is tricky to access - I used a ring spanner and could only get about 1/12 of a turn each time. Watch out for the double washer - it can easily fall down into the engine bay

Remove the securing bolt (1) 12mm on the Fuel Leakage Manifold. See green arrow above

Remove bolts (4) 14mm holding the Fuel Leakage Return Pipe above all of the injectors. These bolts secure the pipe to each of the injectors (there is a hex head in each)

Lift off the Fuel Leakage Return Pipe

Protect each of the fuel points with tissue paper

Remove bolt (1) 12mm on large clamp holding the injector in place

Remove clamp - once this is removed nothing else is holding the injector in place

Remove injector. It will not lift out easily so use some leverage. I used a screw driver and worked my way around it. I also used a small bit of WD40. It took a few minutes but persist. It may work trying to twist it before extracting to loosen it

Remove copper washer down in the injector port. It is about 130mm down and sits on its own shoulder. If it is in one piece (which it should be) it cannot fall down in to the chamber below. I used a wire coat hanger for the wire to pull out the washer. I bent a short 90 degree bend at the bottom and cut it at an angle to leave a sharp point. See top "tool" in the photo below. This allows you to get in between the washer and the shoulder it sits on. Keep at it until it loosens. A small bit of WD40 helps

Clean injector (and remove the old o-ring), clean injector seat, clean injector port (as far in as possible). I used a flat head screwdriver to scrape away the black stuff. It flakes off. I used the second tool in the picture below with some tissue wrapped around the bottom, and stuffed it down into the injector port. This allowed me to scrape away any of the dirt and let it fall into the port. When I was done, I taped a short piece of garden hose onto the end of the hoover and sucked out the gunk that had fallen in. I pulled out the tool and it cleaned the inside of the port as it was withdrawn


Add new o-ring and copper washer. I applied some grease just to hold the copper washer in place as I inserted the injector back into the port. 

Repeat the reverse process from "remove clamp" back up to securing the wire harness

Prime the fuel system


Other Photos:

New and old washers and o-rings. New on left!



Injector cleaned and washer and o-ring attached.



Cleaned injector seat and port.



Damage to Washer:



Dirty Injector:-



Great post Monocle. Saved me a lot of time and money. My injector came out after 40 mins of gentle persuasion so not to bad. Found best way for me was to get it turning first by lots and lots of gentle tapping with a hammer and socket extension. Then levered up slowly with a large screw driver. Only caveat I would add was don't tighten fuel lines till everything aligned properly. Apart from that thanks again.

Share this comment

Link to comment

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now