Injectors
How do you set up injectors? Do you have to pressure test them, if so, how do you calibrate them if they are not set at the correct pressure.
I removed all of my injectors the other day, stripped them down, and layed them out in the correct order. When I went to check my EPC for something, my daughter then mixed everything up!!! :?
The spacers, the springs, the nozzles and the spring washers are all mixed up, I also couldn't find one of the spacers between the spring and the injector head!! :shock:
Looking at the EPC for the spacers, I see that there are about 20 off them different sizes.
What should I do? I put them all back the best I could and made another of those spacers as close as possible to the the rest of them. They were all different, ranging from 1,32mm to 1.54mm thick. The springs seemed to be almost identical.
My engine is now ticking away worse than I started, but without any loss of power.
Any advice from any deisel mechanic out there would help :oops:
I'm not a mechanic but I have read the workshop manual on injectors and this is what it said:
The injectors are setup using a pressure testing device. The new pressure is 120 bar and used min 105bar. The injection pressure is adjusted using the shims between the injector head and the spring. A 0.05 mm difference in thickness results in a injection pressure difference of 3 bar. Clearly if you have mixed up these shims then all the injection pressures will be incorrect. And if you made one yourself then it could be way out. But being a basic engine you have proved that it still runs. I guess the fuel consumption will be not at the optimum.
You need to find a diesel garage with an injector pressure tester and have them set up correctly. But without a supply of shims you will not be able to adjust the value.
It would probably be better ordering new ones as injecotrs do wear out. I have seen mention on the German boards that guys fit the injectors out of the turbo engine which have 135- 145 bar pressure.
Oh Dear, as Roly says you'll have to find someone with a pop tester. Meantime you could visually check each injector by taking them out and tighten them on to the pipes, turn the engine over ( please keep your hands etc. away as the atomised diesel can penetrate skin ) You should have a good clean and even mist spray from each injector and there should be no weeping from the nozzles. You really need to get them to someone in the know with the correct equipment as mentioned above as there are other tests besides the pop test. Things like injectors and diesel fuel pumps are not really D.I.Y. as they require special tools for setting up and calibrating. I would send them off to be overhauled if I were in your shoes and you'll end up with a practically brand new set. Have fun :shock:
Roly,
you say that the pressure is 120 barG for my car. If I buy new turbo injectors that are 135-145 barG, will my pump be able to give that pressure?
How can injectors wear? I have spoken to Scott at Western Mercedes in Scotland to enquire about new springs and spacers, would this be sufficient? I cant see where the injectors can wear anywhere else.
If I buy new injectors for the non turbo, are they already set for the 120 barG? I see on my epc that you have to buy the nozzles separately.
Many thanks for all this help
Martin.
I've not done any work on injectors my self so this is all what I've read only.
I don't know anything about the turbo injectors except what I have seen on the German boards and that is that people are fitting them to the nonturbo engine presumably getting a few extra hp out of it. I can't say what long term effect this may have on the fuel pump. The turbo engine uses a different pump so it may be upgraded . I will try it when my injectors need replacing .
The wear on injectors in usually around the nozzle ends where the fuel exits. The ends wear and the spray pattern gets messed up. As the spring wears the pressure required to open the injector will decrease.
Given the age of you G I would just buy new injectors which will be set at the factory to the required pressure. If there is a decent diesel shop in your town you could buy the nozzles only and get them to rebuild the injectors correctly setup with pressure. That would be just a cost exercise and time off the road etc. Of course you could send them to the UK and have them rebuilt here plenty of Bosch diesel places around. Its common enough job. I wouldn't recommend mucking about with them your self unless you have access to a diesel test rig
I can email you the relavant pages from the workshop manuals if you want
Roly
Way hee, I have just received my workshop manual on DVD, I will install it tonight and let you know.
I have found a deisel workshop in Baku and they tell me that they can set up my injectors,,,,,,,,,,,,,Watch this space!
Many thanks for your help
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