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Old 6th June 2020, 22:06   #1
Arctic
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Default Diesel Brass Leak Off Connectors.

Those of us whom have the diesel R40 or MGZT will have plastic leak off connectors on the injectors, these can and do go brittle over time therefor can fracture or break, thereby causing a leak which will allow diesel to go over the engine.

This preventive problem can be solved by swapping out the plastic leak back connectors with brass ones as such in this how to below.

First purchase the brass connectors from Ebay or a good diesel components shop.



Cheaper not any longer go with the ebay one above.
https://www.dieselcomponentsuk.com/

You will need four connector joints.
1

1A

Once you have purchased your brass connectors, you can tackle the job of changing the connectors over.

Fist use a 5mm socket to remove the three tors head screws holding the electric injector loom to the cam cover.
2

3

With the screws removed and set safe to one side, use a small flat screw driver to pop open the injector connection as here below.
4

Do all four plugs and pull from the injectors one by one then lift the loom out of the way.
5

Lay it on top of the air filter cover in my photo the air cover is missing as I was changing the filter at the same time.
6

Next we/you need to remove the spring clips holding the T plastic leak off connectors into the top of the injectors.
7

8

Use a pair of long nose pliers do remove the spring clips starting at injector 4 on the end of the line.
9

Working your way along to injector 1
10

With all the spring clips removed & put safe with the screws, you can now lift off the plastic leek off connectors from the injectors,do this by pulling upwards.
11

If they will not pull out you can use the small screw driver to pry them upwards, or grip them with the pliers and pull up.
12

Once you have removed the last leak off joint from injector 1 pull the line from the leak back hose.
13

If they will not pull out you can use the small screw driver to pry them upwards, or grip them with the pliers and pull up.
12

Once you have removed the last leak off joint from injector 1 pull the line from the leak back hose.
13

Now you will have the four leak off joints in a row with connecting hoses.
14

15

With the new fuel hose that came with the brass leak off connectors, lay this next to the old set.
16

You now add the stop end brass connector joint into the end of the new hose.
17

You know cut a length of new hose to fit between the next T joint.
18

19

Repeat this until you add the last T joint 3 in total.
20

Now the last joint as been added to the new length of fuel line hose, connect this to the leak back hose.
21

Push in each brass connector into the top of the injectors.
22

Now all the brass connectors are fitted into the injectors replace the spring clips.
23

24

replace the injector loom.
25

make sure the plugs are pushed fully home until they are locked in with an audible click.
26

Now put the loom screws back into the cam cover 5mm socket.
27

The job is now completed replace the engine cover.

As promised to Paul from Brum
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Last edited by Arctic; 31st May 2023 at 15:49.. Reason: Photo Editing
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Old 7th June 2020, 03:09   #2
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Quote:
Originally Posted by Arctic View Post
Those of us whom have the diesel R40 or MGZT will have plastic leak off connectors on the injectors, these can and do go brittle over time therefor can fracture or break, thereby causing a leak which will allow diesel to go over the engine.

This preventive problem can be solved by swapping out the plastic leak back connectors with brass ones as such in this how to below.

First purchase the bras connectors from Ebay or a good diesel components shop.
https://www.ebay.co.uk/itm/281404361492

https://www.dieselcomponentsuk.com/

You will need four connector joints.
1

1A

Once you have purchased your brass connectors, you can tackle the job of changing the connectors over.

Fist use a 5mm socket to remove the three tors head screws holding the electric injector loom to the cam cover.
2

3

With the screws removed and set safe to one side, use a small flat screw driver to pop open the injector connection as here below.
4

Do all four plugs and pull from the injectors one by one then lift the loom out of the way.
5

Lay it on top of the air filter cover in my photo the air cover is missing as I was changing the filter at the same time.
6

Next we/you need to remove the spring clips holding the T plastic leak off connectors into the top of the injectors.
7

8

Use a pair of long nose pliers do remove the spring clips starting at injector 4 on the end of the line.
9

Working your way along to injector 1
10

With all the spring clips removed & put safe with the screws, you can now lift off the plastic leek off connectors from the injectors,do this by pulling upwards.
11

If they will not pull out you can use the small screw driver to pry them upwards, or grip them with the pliers and pull up.
12

Once you have removed the last leak off joint from injector 1 pull the line from the leak back hose.
13

If they will not pull out you can use the small screw driver to pry them upwards, or grip them with the pliers and pull up.
12

Once you have removed the last leak off joint from injector 1 pull the line from the leak back hose.
13

Now you will have the four leak off joints in a row with connecting hoses.
14

15

With the new fuel hose that came with the brass leak off connectors, lay this next to the old set.
16

You now add the stop end brass connector joint into the end of the new hose.
17

You know cut a length of new hose to fit between the next T joint.
18

19

Repeat this until you add the last T joint 3 in total.
20

Now the last joint as been added to the new length of fuel line hose, connect this to the leak back hose.
21

Push in each brass connector into the top of the injectors.
22

Now all the brass connectors are fitted into the injectors replace the spring clips.
23

24

replace the injector loom.
25

make sure the plugs are pushed fully home until they are locked in with an audible click.
26

Now put the loom screws back into the cam cover 5mm socket.
27

The job is now completed replace the engine cover.

As promised to Paul from Brum
Thanks for posting this up again. Cleaning a spare set of injectors I have picked up is my next task, but you once posted a link for the brass kit before, that I have long kept in my watch list. I cannot see any difference in it, except that it is a 5 cyl kit, and it is slightly cheaper, even if it is from the same suppliers! So it will give a spare spring clip and 180 degree piece too

LINK

Also watching a video tutorial on dismantling the injectors (I know you have a how to somewhere also), there was a link for replacement Viton O rings mentioned, with a note saying that they should be replaced everytime the leak off connectors are removed. I dont know how necessary this is, but I think it may be of use to have a reference for these parts. They seem to be expensive for what they are, but they are HERE, if they need to be replaced.
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Old 7th June 2020, 06:24   #3
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Thanks very much Steve for the info
Regards paul
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Old 7th June 2020, 09:07   #4
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well done Steve

Copied into how to section as well
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Old 7th June 2020, 09:27   #5
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[QUOTE]
Quote:
Originally Posted by clf View Post
Thanks for posting this up again. Cleaning a spare set of injectors I have picked up is my next task, but you once posted a link for the brass kit before, that I have long kept in my watch list. I cannot see any difference in it, except that it is a 5 cyl kit, and it is slightly cheaper, even if it is from the same suppliers! So it will give a spare spring clip and 180 degree piece too

LINK
Hi Alan.
If you use the link in my thread for the dieselcomponetsuk.com

they have sets of four or five cheaper than ebay. (not any longer so stick with the ebay link. )

https://www.dieselcomponentsuk.com/p...cylinder-brass

Five
https://www.dieselcomponentsuk.com/p...cylinder-brass

Quite a lot of other items too.

Update since this post was made the prices have doubled from dieselcompoentsuk.com. therefore the ebay link is best

https://www.ebay.co.uk/itm/173091164085
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Last edited by Arctic; 18th October 2021 at 22:30..
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Old 7th June 2020, 13:16   #6
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[QUOTE=Arctic;2817141]
Quote:

Hi Alan.
If you use the link in my thread for the dieselcomponetsuk.com

they have sets of four or five cheaper than ebay.

https://www.dieselcomponentsuk.com/p...cylinder-brass

Five
https://www.dieselcomponentsuk.com/p...cylinder-brass

Quite a lot of other items too.
Doh! Even better! I didnt notice the Diesel Components was a link - my apologies (It was very late, and I had just finished transcribing an 1828 tithe book for my regular work lol)
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Old 7th June 2020, 15:29   #7
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Fantastic write-up, and the first thing I did to my ZT-T and my B*W (no swearing here!) too.
Nice to see lots of pics without Photobucket doing 'their thing' on them!
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Old 7th June 2020, 16:23   #8
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Quote:
Originally Posted by DMGRS View Post
Fantastic write-up, and the first thing I did to my ZT-T and my B*W (no swearing here!) too.
Nice to see lots of pics without Photobucket doing 'their thing' on them!

Ever thought about getting some in stock, if you could do them for a similar price folks might be interested, myself included.

Martyn
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Old 18th October 2021, 18:48   #9
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Thanks very much for the guide. Did this today and it went nice and smoothly after having read through this how to.
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Old 18th October 2021, 22:36   #10
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[QUOTE]
Quote:
Originally Posted by clf View Post
Quote:
Originally Posted by Arctic View Post

Doh! Even better! I didnt notice the Diesel Components was a link - my apologies (It was very late, and I had just finished transcribing an 1828 tithe book for my regular work lol)

Hi Alan
The above is now irrelevant as their prices have doubled since this thread so best to stick to the ebay link i have posted in this thread.

https://www.ebay.co.uk/itm/173091164085
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Check out our Nano meet dates
http://www.midlandsnanomeets.co.uk/

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