Diesel Brass Leak Off Connectors. by Arctic


User avatar
Arctic
(Trader)
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 here.
https://www.dieselcomponentsuk.com/prod ... nder-brass

https://www.dieselcomponentsuk.com/

You will need four connector joints.
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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.
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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.
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Do all four plugs and pull from the injectors one by one then lift the loom out of the way.
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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.
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Next we/you need to remove the spring clips holding the T plastic leak off connectors into the top of the injectors.
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Use a pair of long nose pliers do remove the spring clips starting at injector 4 on the end of the line.
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Working your way along to injector 1
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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.
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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.
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Once you have removed the last leak off joint from injector 1 pull the line from the leak back hose.
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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.
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Once you have removed the last leak off joint from injector 1 pull the line from the leak back hose.
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Now you will have the four leak off joints in a row with connecting hoses.
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With the new fuel hose that came with the brass leak off connectors, lay this next to the old set.
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You now add the stop end brass connector joint into the end of the new hose.
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You know cut a length of new hose to fit between the next T joint.
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Repeat this until you add the last T joint 3 in total.
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Now the last joint as been added to the new length of fuel line hose, connect this to the leak back hose.
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Push in each brass connector into the top of the injectors.
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Now all the brass connectors are fitted into the injectors replace the spring clips.
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replace the injector loom.
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make sure the plugs are pushed fully home until they are locked in with an audible click.
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Now put the loom screws back into the cam cover 5mm socket.
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The job is now completed replace the engine cover.
Pearl Firefrost
ARCTIC

Posted 06 Jun 2020, 21:42 #1 

Last edited by Arctic on 31 May 2023, 15:37, edited 2 times in total.

User avatar
MrDoodles
I don't own a diesel, but yet another great "how-to" :thumbsup:
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Posted 07 Jun 2020, 10:18 #2 

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Duncan
Excellent, thanks Steve. Just ordered a set. Much cheaper direct than via ebay!
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Posted 10 Jun 2020, 08:59 #3 

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Bermudan 75
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Posted 12 Jun 2020, 16:16 #4 

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Jürgen
(Site Admin)
Thanks, Steve, as always very good step by step instructions. :thumbsup:

Bermudan 75 wrote:Is this the right set?

https://www.dieselcomponentsuk.com/prod ... nder-brass

I could find just three different kits on that side and your linked one has the right amount of t-connectors. So I'm confident that you're right Mike.

Posted 13 Jun 2020, 10:57 #5 

User avatar
Duncan
Surely Mikes link is for a 5 cylinder. We need 3 tees and a right angle don't we?

I bought this one and it seems right though not yet fitted:
https://www.dieselcomponentsuk.com/prod ... -90-2x-180

EDIT: And now I see it's wrong because it has only 2 tees. This is the one I intended to order:
https://www.dieselcomponentsuk.com/prod ... nder-brass
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Posted 15 Jun 2020, 08:52 #6 

User avatar
Jürgen
(Site Admin)
Duncan wrote:This is the one I intended to order:
https://www.dieselcomponentsuk.com/prod ... nder-brass

Perfect, Duncan, I didn't see that one, only the one with two 90° parts and the one for 6 cylinder engines.

Posted 15 Jun 2020, 14:32 #7 

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Bermudan 75
I have now ordered the kit referred to by Duncan.
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Posted 15 Jun 2020, 17:36 #8 

User avatar
Duncan
And my replacement Tee arrived today since I accidentally ordered the one with 2x90 and 2xtee.
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Posted 17 Jun 2020, 16:22 #9 

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Arctic
(Trader)
Bermudan 75 wrote:Is this the right set?

https://www.dieselcomponentsuk.com/prod ... nder-brass


Hi Mike.
Yes those will fit, but as Duncan says we only need the four 3T & 1 90 as here below.
https://www.dieselcomponentsuk.com/prod ... nder-brass

I order the ones in your link because i change quite a few if i service anyone's diesel for them, i then after four sets only need to get a 90 joint
Pearl Firefrost
ARCTIC

Posted 18 Jun 2020, 19:55 #10 

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Arctic
(Trader)
Duncan wrote:And my replacement Tee arrived today since I accidentally ordered the one with 2x90 and 2xtee.


Duncan I did that once myself ages ago, but they got used up, also the remaining hose can be used to replace the vacuum hose which connects to the EGR (Exhaust Gas Recirculation Valve) solenoid and the brake servo valve, they chaff and can get holed if they do your brakes can become very hard to push and do not work as good, it is dangerous so worth checking

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Better safe than sorry.
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Pearl Firefrost
ARCTIC

Posted 18 Jun 2020, 20:31 #11 

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Duncan
Steve, I will end up with a spare 90 you can have because of my error!
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Posted 19 Jun 2020, 20:35 #12 

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Arctic
(Trader)
Duncan wrote:Steve, I will end up with a spare 90 you can have because of my error!


Hi Duncan
Thank you i am sure we will meet catch up either later this year or early next :lol:
Pearl Firefrost
ARCTIC

Posted 19 Jun 2020, 22:31 #13 

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Arctic
(Trader)
These are a bargain at the moment don't miss out.

https://www.ebay.co.uk/itm/173091164085
Pearl Firefrost
ARCTIC

Posted 06 Jul 2021, 23:53 #14 

User avatar
Arctic
(Trader)
I just bought a set of brass leak off connectors from a chap on the forum, as he no longer has his R40 but the link below is still good at £19.00

https://www.ebay.co.uk/itm/173091164085
Pearl Firefrost
ARCTIC

Posted 21 Nov 2022, 11:06 #15 


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