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  #1  
Old 25th-June-2010, 23:26
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Cool howto: 200tdi injector refurb

Good evening lads and lasses,

I had my injectors checked out properly earlier on today, on a very nice 14,000 bit of Bosch testing equipment. It's shown that three out of four nozzles are well past their best but instead of paying the usual 200 - 250 for reconditioned units, the technicians walked me through how to disassemble and and then re-assemble my injectors with new nozzles in a D-I-Y fashion. I have ordered a set of four nozzles at a cost of 80 from another local diesel injection specialist. He tells me that these nozzles are made on the same line as the genuine Bosch components in a Bosch factory but are un-branded. I don't really believe that but I'm willing to give them a try, with a saving of 86 over the Bosch nozzles. I have already cracked open and ultrasonically cleaned every component of two of my injectors and I intend to do the other two tomorrow. All being well, the new nozzles should be ready for me to collect on Monday and then all I have to do is whip the end caps off, lift my old nozzles out and slip the new ones in I'll let y'all know how the engine goes after I've re-fitted the injectors and all being well I'll have done just as good a job as the man in the workshop for a lot less money.

Here are a few pictures I took just for reference. Don't worry! They have been re-assembled in a pristine clean environment, not the horrible splintery, dusty outside area that you can see in these pictures. Also, one of the components is out of place in these photos. I found this when I tried to re-assemble the injector and the internals just rattled around. That problem is now solved.

The results for each injector as provided by the Bosch testing equipment. As you can see, the wear is pretty even which means there is nothing untoward going on inside the body, just general nozzle wear:









Cracked open the first injector. Quite simple really. Support the injector body in a vice ensuring that the jaws are only contacting the flat surface of the injector and then use a deep 15mm socket to crack the end caps / nozzle holders off. Three were relatively easy, one took a bit more effort but they all cracked off without too much hassle. I was surprised to see how many solid / gritty particles there were inside what I would have expected to be a very clean, well lubricated environment:







Old Nozzle wear is clearly visible towards the end point of the needle. This wear (as well as the wear in the nozzle housing) is what reduces the 'pop' pressures and diesel spray pattern in my case. I expect that when I install my new nozzles, the lack of wear should bring my pop pressures back up to where they should be and obviously restore the spray pattern. I suspect they have never been changed before, so they could well have covered 100,000+ miles:



Reassembling the injector after ultra-sonic cleaning. I took Buster's advice in the end and decided to go ahead with my mums el-cheapo ultra-sonic jewellery cleaner and the results were stunning. Simply put hot tap water into the bowl along with some of the jewellery cleaning solution that came with it, turned it on and suddenly clouds of black carbon come swirling away from everything inside! It only works on 3 minute cycles but I found ten cycles (30 minutes) was more than enough to bring everything up nice and clean (i.e. the solution barely sooted up). I have also cleaned and re-installed the old nozzles just so that everything is kept in place inside the injector body. All that needs doing now is the cap removing, the old nozzle removing and the new one fitting in its place. The new nozzles should be ready for me to collect on Monday, so I'll post more then :



-Pos

Last edited by pos; 26th-June-2010 at 21:32.
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Old 26th-June-2010, 01:45
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Default re: howto: 200tdi injector refurb

well I have just taken my injectors to a small diesel engineer for testing and/or repair and was told (depending on what was needed) costs would be between 12 and 50 per injector, needless to say it was the latter and I came home with 4 (New looking) injectors, but with 234 less in my wallet. Hope it will be worth it.
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Old 26th-June-2010, 11:08
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Default re: howto: 200tdi injector refurb

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Originally Posted by ormondstreet View Post
well I have just taken my injectors to a small diesel engineer for testing and/or repair and was told (depending on what was needed) costs would be between 12 and 50 per injector, needless to say it was the latter and I came home with 4 (New looking) injectors, but with 234 less in my wallet. Hope it will be worth it.
That's exactly the reason why I'm having a go at it myself! Were you experiencing power loss at all, or did you just want to have them checked? Could you let me know what difference it makes to your power when you get them fitted? Only one of my injectors had an acceptable spray pattern and I was told that it will make a tremendous difference to power and economy.

-Pos
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Old 26th-June-2010, 21:06
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Default Re: howto: 200tdi injector refurb

I'm in the middle of a 19j to 200Tdi swap and wanted to do some prep of the new engine, when I fit it (about mid august) I will let you know how it runs.
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Old 26th-June-2010, 21:14
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Default Re: howto: 200tdi injector refurb

mite be useful to have this in the general Q's and A's bit please
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Old 26th-June-2010, 21:25
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Default Re: howto: 200tdi injector refurb

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Originally Posted by The Mad Hat Man View Post
mite be useful to have this in the general Q's and A's bit please
Finally! I may well actually have done something of use on here This is still a bit of a work in progress at the moment and all being well, if the end results are good, I'll do a more detailed right up with some of the steps in between. I thought it would be interesting for everyone to have a look at anyway. The Internet seems to be very scarce of anything related to dismantling and reconditioning Land Rover injectors, particularly 200TDi units which are very expensive in comparison to the closely related 300TDi injectors.

-Pos
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Old 26th-June-2010, 21:30
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Default Re: howto: 200tdi injector refurb

as an aside - can yu fit a 300 head on a 200, or 300 injectors into a 200, coz I thught the injuns were basically the same block?
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Old 26th-June-2010, 21:41
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Default Re: howto: 200tdi injector refurb

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as an aside - can yu fit a 300 head on a 200, or 300 injectors into a 200, coz I thught the injuns were basically the same block?
Not so easily, there are subtle differences unfortunately. 300Tdi injectors, although they look pretty similar to 200Tdi injectors (there are visual differences) are built with different rated components. The nozzle holes are located in different locations so that the atomised diesel spray is aimed towards the more central combustion chamber on the 300Tdi piston crowns. A 200Tdi has combustion chambers which are off-set, either more towards the left or the right hand side of the engine and the 200Tdi nozzles are designed to suit. 300Tdi injectors also open at different primary and secondary pressures, both of which I believe are slightly higher than those of the 200Tdi (it could be the other way around) but I imagine you'd only have to swap the springs in order for this to be rectified. The 300Tdi injectors are also mounted slightly differently to the 200Tdi injectors, both in the angle that they sit in the cylinder head and in the height of the face which the securing bracket holds in the injector down into the head. This can apparently be solved via the fabrication of brackets although I've never found any information / photos about a few that already exist.

As for the 300Tdi head onto a 200Tdi, it's possible, even the head gaskets are identical. The only differences that I'm aware of are the rockershaft, push rods and manifold mating surfaces, all again which could have work arounds. The cylinder blocks are also different in terms of lift pump and oil filter locations but I'm not sure about any of the top surface stuff like push rod holes and cam shaft / followers etc.

-Pos
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Old 29th-June-2010, 23:40
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Default Re: howto: 200tdi injector refurb

A nice new set of Italian made 'Firad' nozzles arrived today, ready to be installed into my 200tdi injectors. Information regarding this manufacturer was very scare on the internet, but the few gems which did show up as the result of a google search proved the brand to be both reliable and well made. (see website - ::FIRAD RESTYLING::) Fitting the nozzles was easy, I simply whipped off the end caps / nozzle holders, removed the old nozzles and installed the new ones in their place. The end caps are only formed from a thin steel alloy, so they just need to be nipped tight;- there's absolutely no need to get a breaker bar on there, just a 15mm spanner to nip them up and then tighten them up an extra 15-20 degrees.

I installed al four injectors with new copper sealing washers and new copper leak off washers and started the engine. It fired up after a little priming and, like a giddy child, I took it for a test drive. The results are tremendous :d The increase in torque is extremely noticeable, pulling away from 30 in 5th is a painless task and the power on hills has been doubled. I also noticed that the engine idle is a lot smoother and engine noise has been reduced. It is smoking a little, so I'm going to adjust my fuel down slightly tomorrow and play with the diaphragm until I get it spot on.

Generally speaking though, it has been a very worthwhile experiment, with similar results (I expect) to those that you'd get from a Diesel mechanic who might charge you anything between 200 to 260 for injector reconditioning. The total cost to me for the refurb has been 87 for a set of four nozzles. I also had use of my Mum's ultrasonic jewellery cleaner, something which I believe is essential to ensure that you get the internal components of the injector as clean as possible.

I'm going to give it a good weeks test and then take the injectors out for testing again. All being well, they'll be on the mark and then I wont have to worry about them again, well, at least not for another 100,000 miles or so.

-Pos
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Old 30th-June-2010, 10:14
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Default Re: howto: 200tdi injector refurb

Good write up POS!
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