Bad injector leak help!!!

[Gator79]

Well more of a horrible spay out out the injector halfs and the top of the injector union.
Swapped out with a different injector same problem.  Am I looking at something that is wrong with the pump, the head or did I just put an old injector with the same problem in.

[burn_your_money]

Your line probably has a hairline crack in it. While looking at that, check to see that all 4 pump mounting bolts are present and secure

[Gator79]

But could that cause it to come out the halves?

[ORCoaster]

Are the two halves torqued to proper ft/lbs?  Mine were leaking so I torqued them hot much like you do for a head gasket.  Solved the weeping problem and I bet I didn't move them a few mm tighter together.  Barely could tell they moved at all except by looking at the painted dab from when they were rebuilt a bit ago.

[theman53]

Injectors could be cracked or the shim wasn't lapped together as Vince Waldon had put a link to.

[burn_your_money]

Sorry, when you said injector union I thought you meant the top where it meets the line.

Are you using the proper 27mm socket to remove the injectors or are you using the smaller (17mm??) flats on the top half?

[Gator79]

The problem started with a running car. I have never touched that injector only the lines since I replaced the pump, witch was a few thousand miles ago and every thing has been fine until now.

Replaced the one injector with New heat shield and injector, tourqed to 51ft. And same problem.

Going to replace the hard line with a new one and see what happens.

[Gator79]

And the winner is Burn-your-money with the cracked hard line.

Now the problem is what injector line do I need.

I have the 1.9 n/a motor with a 1.6 td pump and I'm assuming 1.5/1.6 injectors.


I picked up a new 1.5 diesel line and it doesn't fit.

Did the td have different lines or am I thinking wrong and will I need to find 1.9 lines.

[libbydiesel]

The 1.9 has a block that's 1/2" taller than the 1.6.  Because the pump is bolted to the block and the injectors are bolted to the head, none of the 1.5 or 1.6 lines will fit without bending.  The 1.9 pump had long delivery valves, the 1.6 had short delivery valves.  Unless someone swapped the longer delivery valves into your 1.6 pump, AFAIK there aren't any stock lines that will fit without bending which is probably why yours cracked. 

[Gator79]

Left is the old one and the right is the 1.5 hard line.



From what I have found the aaz and 1y Lines don't evan look like that.

If any one has an idea what it came from and where to get one please let me know.

[libbydiesel]

That's an AAZ line.

[burn_your_money]

That's an AAZ line.

X2

Take a picture of the pump where the lines hook up and also of your injectors please.

I'm thinking if you have a 1.6 pump and 1.6 injectors on a 1.9 engine it should still be the same distance from the pump to the injectors as the 1.6. I could be wrong though, I haven't tried it. I know the block is taller but they may have moved the injection pump that 1/2" as well. Perhaps Andrew knows definitively though. 

[libbydiesel]

Interesting thought.  I don't know definitively.   

[R.O.R-2.0]

That's an AAZ line.

X2

Take a picture of the pump where the lines hook up and also of your injectors please.

I'm thinking if you have a 1.6 pump and 1.6 injectors on a 1.9 engine it should still be the same distance from the pump to the injectors as the 1.6. I could be wrong though, I haven't tried it. I know the block is taller but they may have moved the injection pump that 1/2" as well. Perhaps Andrew knows definitively though. 

if you put a 1.6 fuel system on a 1.9 engine, you have to BEND THE CRAP out of the lines.. trust me, ive seen it done a few times. looks HORRIBLE..

the DECK of the block is the ONLY PART that they raised 16mm... everything else on the engine is in the SAME location as the 1.6 is..

but the DECK is taller.. and only the deck.. you CAN bolt a 1.6 pump and injectors to a 1.9, but you have to DESTROY a set of 1.6 lines to get it all hooked up..

there is a guy local to me, has a 1Y in his caddy, with a 1.6 fuel system.. and the lines are mangled to fit..

[libbydiesel]

Burn, I just measured to be sure, and the 1.9 pump location is the same as the 1.6 location relative the crank and so it is an extra 1/2" lower relative the deck/head/injectors.  With the taller height of the 1.9 dual stage injectors and the longer 1.9 delivery valves, the difference in distance between the delivery valve union and injector union for injectors 1 and 2 is extreme.   

ROR, if 1.9 delivery valves and injectors are used on a 1.6 pump bolted to a 1.9 engine, the 1.9 lines will fit without modification.

Having fairly limited experience with the AAZs, weren't the early ones equipped with single stage injectors and so a different set of lines also?