Leaky injector

So I was leaving a venue and wondered why I could actually see my fuel needle dropping as I drove. It had to be a leak, and I remember that the night before, after using more fuel than I should have needed to, I saw smoke coming from under the front of the van when I was reversing. I leaned out the window with a torch and it was not the exhaust, so I wondered if it was a leak on the EGR system again. I was tired so thought no more about it and went to bed. 

So the next day leaving the venue and heading back to Durham and watching that needle dropping I knew it was a diesel leak so I got stopped as soon as I could and I saw it pouring out from under the van. Turning off the engine stopped it and as it was coming from the offside I guessed it might be the fuel pump. However when I got the bonnet up I saw instantly that the return pipe or leak off pipe as some call it had come off the injector. 
Everything was covered in diesel splash: the battery, the brake and steering reservoirs, the accessory belt, electrics, it was literally everywhere. It pumps out with some speed if you take off the return pipe, and that had been pouring for about 15 miles. I’d lost almost a half tank of diesel, about 30 litres. 

I knew straight away why the return pipe was off. I could see that the small wire clip that holds it onto the top of the injector was not there. A few thoughts went through my head like; did it just pop off? Was it rusted and broke off? Was it not put on properly by O’Connors when they replaced the engine? As I thought that last thought I also noticed that there was no clip on any of the other 3 injector return pipes. There was my answer, this was yet another example of O’Connors shoddy work. He had not replaced the spring clips.

An image of the injector leakj off pipe held in place by duct tape
Showing my improvised pipe clip

I rang him but was told ring back the next day and they would try and find some. There’s no arguing with them I tried before when I got the engine swap done, so I just hung up. The next day I rang them back and they said they had some on order and would get them Friday. So I rang Springfield Peugeot in Gateshead who told me you can only get them with a new injector for £400 lol That’s not true at all, genuine Peugeot parts on ebay have them for £3.49 a set. 🙂
Not wanting to wait for ebay or til Friday I decided to go to a local scrapyard. But first I’d have to cure that leak.

Luckily there’s a metal bracket above the injector which I know as a pain as it has to be removed to get that injector out. So I used some duct tape, folded over many times to create a thick wad, and then  jammed it between the top of the return valve and the metal bracket to make sure the valve did not come out again. 

You can clearly see in the photo all the diesel covering everything in the bay, and on top of the left most injector, the wad of duct tape that was holding it in place. 

With this arrangement it still leaked but only barely, so that was me sorted for the time being.  I got to the scrapyard without issue and got 4 clips and a new piece of return end pipe for a fiver, job done. 

Oh it also cost me £8 at Halfords for a tin of brake cleaner which I used to clean the worst of the diesel spill from the rubber hoses, electrical wires and fluid reservoirs. The rest of the block and the engine mount need a better cleaning though, I’ll probably have to Gunk it and use a high pressure hose to get it properly clean. 

There is definitely an argument to be had about paying inexpensive garages to do complicated jobs. Using O’Connors has cost me about £500 more than it should have done, in extra costs on hire cars, accommodation, new parts and of course a half a tank of diesel and a lost day dealing with it. 

Back to that same old question: where the heck do you find a reliable garage that does not charge £100 an hour like Peugeot dealers do? One Peugeot main dealer quoted me £3200 to swap the engines. So I guess I’ve still saved £2000 by going to a backstreet garage.

PS: I think that particular injector needs replacing anyway, and has done since the other engine, but aside from that this new engine seems to be running really well. Touch wood!

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