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  1. Important:- I would strongly advise that you do not undertake this task when the engine is hot. I found that the fuel return lines bend when loosening the banjo bolts. Luckily the lines didn't split and i was able to bend them back to their original shape but it was extremely awkward and risky. 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). Method:- 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 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 - hidden behind the electrical connector on cylinder #1 in the photo. 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. However, it is advised that the fuel line bolts (banjo bolts) are only hand tightened until everything is back in place - then tighten away (credit @kenwoodIS) 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:-
  2. Hi All, My car was diagnosed with an injector seal leak on cylinder 2 and a suspected compression leak. This was diagnosed by the AA and confirmed by JEM Car of Colindale. They have recommended a main dealer for the fix. Can someone please recommend a good independent to sort this out please?.....or any suggestions. Please see attachment Li.
  3. Hi all Today after almost a year I decided to clean the EGR valve as it had been 10K since I last did it and the car was feeling a bit sluggish. When I removed the engine cover, to my surprise it was covered in sort of black tar (but hard to the touch) around one of the injectors and burn marks and similar crust on the underside of the enigne cover as well. When I started the car, with the bonnet up and engine cover off, it was like a steam engine. It was blowing sort of steam, stream from the injector on every turn of engine about every four ticks I presume. So.. I dont know how long its been blown for as I had been feeling the car was becoming a bit sluggish and MPG was going down quite a bit and I thought it was the EGR valve. Problem is that when the engine cover was on and I was usually sat in the car with the windows up and AC on, I would not have heard that steam engine blowing So I am a bit scared now what to do about it. Its on 118000 miles now. The head gasket should be OK as the pink radiator fluid is still pink and no residue inside the engine oil cover. I am trying to post some pics with this thread but don't know if they will come out properly. Any comments? suggestions what to do next?
  4. A couple of weeks ago I was driving to the coast, at some traffic lights I put the window down and heard a loud ticking sound coming from under the hood. It turns out this is a faulty injector. I took the car to a garage who confirmed this. Being covered by warranty direct (100% labour & 50% parts), I called them to authorize the claim. Later the same day I was told that they would pay £449 and I was to pay another £380-ish. I thought this was better than nothing and asked the garage to go ahead. (£390 for the injector, £25 seals +VAT). A full 5 working days later I was told that they have managed to remove the injector but NOT the injector seal, which is stuck at the bottom. It has now been 9 working days and the garage have given up. They have recommended I either take the car to another garage, but that it would have to be towed, or they remove the engine, the head, remove the seal then put everything back together. I called warranty direct to authorize all the extra labour, however they said that they cover work on the injector, not the seals, therefore I would have to pay for this myself. They told me that there are companies out there with specialist tools, who can remove stuck seal. I am in Cambridge, can anyone please recommend such a company? I managed to find one in north Yorkshire, but they do a minimum of two and would charge about £300 because of the distance. Please advise, Thank you.
  5. Hello All, Having recently bought an IS220d I have been experiencing a number of problems: At the end of first day of owning the engine management light came on and when I used the OBD reader it gave out a P2002 code. I found a local company that had experience with removing IS220d DPF, blocking the 5th injector and wiring in the emulator. I took the car to them the following day and the removed the DPF. After a couple of weeks of driving the car back I noticed white smoke on cold star up which would last for approx 30-60 secs and then disappear when I drove off. I also noticed that there was little hesitation between 1200-1500 rpm on light throttle. The engine management light then came on again, this time error code was P0400, EGR fault. So I had the EGR cleaned and the error code wiped. However the problem still remained. Last Friday I took the car to a diesel specialist to have the fuel pump and the injectors checked. They told me that injectors 3 & 4 readings were not what they should be and they went on to remove them to carry out further tests. The bench tests indicated that injectors 3 & 4 were faulty. I've since done a search on eBay and I've found the following injectors: I also found some other sellers on eBay but the injectors don't have the tail coming off them like my current injectors do? Does anyone know of any other places where I could purchase these injectors at a more competitive price?
  6. DENSO 450 cc Toyota Lotus 1ZZ 2ZZ x 6 I have been looking but I have noticed a lot of clones/cheap knock offs so want to be sure of the quality of what i am getting although this said i dont want to pay through the roof. If anyone knows of a good place to get these or even better has them for sale themselves give me a shout. Any help appreciated folks. :)