injectors

Having looked at Buster's guide to changing the injectors I started to think....

How often do they need changing?

When do you know they need changing (apart from total failure)?

Is it better to change the whole thing or just the tips (I've spotted some on tips on ebay for £80).

200tdi motor:blabla:

bluehaze said:

Having looked at Buster's guide to changing the injectors I started to think....

How often do they need changing?

When do you know they need changing (apart from total failure)?

Is it better to change the whole thing or just the tips (I've spotted some on tips on ebay for £80).

200tdi motor:blabla:

Click to expand...

In most cases where a diesel engine is worked hard (i.e. pulling trailers on a daily basis) or where the engine may have a great number of hours on the clock, it is common to replace or refurbish the injectors at anything between 80,000 and 120,000 miles depending on the kind of use that the vehicle has had. Common signs of injector wear are starting problems, consistant black smoke, loss of power (more noticeable on hills), erratic idle or knocking. The injectors in my 200tdi had never been touched for over approx. 200,000 miles so I thought it was wise to get them tested and give them an overhaul. I wrote up a vague guide here - http://www.landyzone.co.uk/lz/f7/howto-200tdi-injector-refurb-110575.html - which will show you how to dismantle the injectors in order to fit new nozzles. In most cases, there is absolutely no need to replace the entire injector, it is usually just the nozzle and a couple of parts inside the injector body that wear. If you go down the fitting new nozzles route, you will need to take the injectors to a diesel shop to have the pop pressures set following installation. 200tdi injectors are supposed to have a primary opening pressure of 200 atmospheres. My local diesel man set them to 205 atmospheres so that once they had worn in, they would be sitting at or just slight above the correct opening pressure. You'll also find that 200tdi injectors cost within the region of £110-£140 each, as opposed to a 300tdi injector which is around £70 a piece. They are quite different however.

I'd first reccomend that you get them tested at your local diesel specialist and insist that you watch the test just to make sure that you are not being fobbed off. Most places will probably just have a 'pop tester' which is essentially a manually primed hydraulic pump that forces diesel into the injector. When the pressure from the pump overcomes the resistance of the first stage injector spring, the injector nozzle opens or 'pops' and a gauge gives the opening pressure for the injector. You can also see the quality of the injector nozzle spray pattern, which should be three or four perfectly straight lines of diesel as opposed to a fan of spray. Holding the injector just below opening pressure for five to ten seconds should also reveal whether or not the injector nozzle or body is leaking. More advanced injection specialists will have a very nice piece of Bosch equipment which performs quite a few clever tests and then records the data on a chart, but it is essentially a similar test.

Do not buy the nozzles that you see on eBay, and do not be tempted to buy 'genuine' Bosch nozzles either. They are not what they used to be. Most Bosch nozzles are now made in India and I have heard reports from two independant diesel injection specialists who have had problems with the injector needles sticking in the nozzle body. I used Firad nozzles in my refurb and 5000 miles on, everything seems to be superb. I am certain that Bosio will also make a nozzle to suit although they tend to make performance nozzles which allow for more fuel displacement per injection cycle. They a very popular with the Volkswagen diesel crowd

-Pos

Thanks pos - wish I still lived in York as I could have gone there. I'll find a local place down here before Summer as we're off to gay paree for hols!

Anyone recommed anyone down here?

bluehaze said:

Anyone recommed anyone down here?

Click to expand...

Nope - but if you find anywhere good, let us know!

I have just looked at this for my 200TDI and as its on 120k miles and I had issues on getting up hills at anything over 40 mph on motorways in Europe last year I am going to take them in.

Below is a local company and what they said to give you some ideals of pricing.

He will test my old ones for free and turn around a refurb of the old ones in 2 days so I am whipping them out now.

////////////////////////////////////////


I can either test and recondition your original injectors or I can supply you with the following,
[FONT=&quot]A set of reconditioned service exchange injectors at £ 180.00, old units to be returned see below.
Postage £ 12.00[/FONT]
[FONT=&quot] [/FONT]
[FONT=&quot]or if you can send your units in the price will be the same.

This price includes the following,

a.. Fitment kit comprising of the necessary heat shields, washers, grease,

b.. Fitment instructions including torque settings.

c.. Postage via Royal Mail Next Delivery or Parcel Force courier.

d.. A Free Post Returns label for you to return the old units.

e.. V.A.T.

Please Note that your old injectors must be returned in a "off the engine condition" this means that there must be no external damage to the injectors,[/FONT]
[FONT=&quot]Should any of the injectors be damaged or not returned the surcharge of £ 30.00 each will have to be charged to replace the damaged injector/s

[/FONT]

spam.

I have just looked at this for my 200TDI and as its on 120k miles and I had issues on getting up hills at anything over 40 mph on motorways in Europe last year I am going to take them in.

Below is a local company and what they said to give you some ideals of pricing.

He will test my old ones for free and turn around a refurb of the old ones in 2 days so I am whipping them out now.

////////////////////////////////////////


I can either test and recondition your original injectors or I can supply you with the following,
A set of reconditioned service exchange injectors at £ 180.00, old units to be returned see below.
Postage £ 12.00

or if you can send your units in the price will be the same.

This price includes the following,

a.. Fitment kit comprising of the necessary heat shields, washers, grease,

b.. Fitment instructions including torque settings.

c.. Postage via Royal Mail Next Delivery or Parcel Force courier.

d.. A Free Post Returns label for you to return the old units.

e.. V.A.T.

Please Note that your old injectors must be returned in a "off the engine condition" this means that there must be no external damage to the injectors,
Should any of the injectors be damaged or not returned the surcharge of £ 30.00 each will have to be charged to replace the damaged injector/s

Click to expand...

Who does this service and where are they?

United Diesel Fuel Injection Services
Diesel Injectors | Diesel Engine Problems - United Diesel Ltd

I know nothing about them but the site looks good, they definitely seem more technical diesel testers than a garage trying to bolt that bit on the side. Keith Da Costa was the chap I corresponded with on email.

Looks good - I'm moving near there at the end of the year so will further investigate then.

Has anyone used these guys?

tried and tested company - have done 100s of little jobs for me over the years

GW Dale Diesel Engineers - Diesel injector and diesel fuel pump repair sales and servicing

Hi Sean,

I'll visit both of these places when I move up there. I've got a spare set of injectors that I would like checking and reconditioning if necessary, but as usual don't want to spend a fortune or have them done by a cowboy!

Many thanks.

Where are you moving to ?

I should have mine out soon and will let you know how it goes.

Moving to Litchfield at the end of the year. This will be a Christmas time job.

I have just been to united Diesel. I would say they are a great company. I dropped Keith the owner an email to say I was stuck with the last injector so I would be late bringing my set in.

He said with the right tools its easy enough and offered to loan me a slide hammer to remove the last one, and loaned me a tool for removing the carbon from the washers in order to remove these.

Both of these I have with me now, I mentioned I had scuffed one of the injectors by the screw, and he said thats as I used spanners and said he can machine it down to as good as new.

Perfect service as he could have tried to charge for a whole new injector.

Fingers crossed I will have them all back to him by the end of the day.. I thought any commercial company wouldnt loan tools in this day and age. The Unit they have is not a garage but very much a lab environment with machines etc and some fella dropped in a bucket of injectors from transit vans whilst I was there to be tested.

Wow what a difference a slide hammer made... last injector took about 3 minutes...

I took the 4 in and straight away Keith said come through. He put each of my injectors into his machine and I watched Diesel spraying through them. It was far from a fine mist and you could see where it was blocked. Not only that it was reading the pressure below 200 PSI as it should so he is going to re-con the 4 for me.

It was awesome to watch.

All done and I am very happy, the condition of the injectors is well beyond what I had expected. One was beyond saving so it cost me an extra £30 for Keith to supply a replacement.

Total cost £216