[diesel_mercedes] Basic Injector Service

 



Pretty much yes .

I was reading the Factory Service Manual and it says they want me to lap the sealing surface of the injector body halves , this of course would tend to raise the pop pressure point....

You're also supposed to clean the disassembled injector parts in a sonic cleaner , I happen to have a small one a grateful Customer gave me ,  then you're supposed to clean the nozzles with brass brush bristles (brass only !)

 I'm not sure I want to get that involved with it all , so far I've just cleaned and tested bunches until I get a set as necessary for that time , then I give the other injectors away to others who'll overhaul/service/rebuild them .

Max wrote :

So............, you adjust the pressure by adding or removing shims? Then re-test till you get it within specs?  Are they different thickness? On China Diesel all you did was turn a screw. Max
 

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[diesel_mercedes] Injector Heat Sheilds [4 Attachments]

 
[Attachment(s) from Nate included below]


6.5.16

Sigh ;

Pic. # 1 is three fold : upper right are the damaged and broken heat shields I runied , three have the centers punched out , two are now concave , all are scrap and in the trash now .

Middle right is a set of really clean and good condition early design heat shields from a 1980 W116 .

As I've never seen these before I put them aside in my spare injectors box .

Lower left is the set of five I wound up using , I actually had 9 to choose from three had some pitting on the bottom side that was revealed after I cleaned them , I tossed those in the trash too to prevent the possibility of my using them " temporarily just for now " or other nonsense .

I went to my favorite local Junk Yard this morning (after taking Son,Grand Daughter&DIL out to breakfast) and found more Mercedes diesels than their web site said they have .

Question : what do you do when you have a super clean old Mercedes OM617 engine that doesn't leak and has obviously been worked on not long ago as evidenced by multiple new Dealer parts , clean oil and no sludge inside it ? .

Answer : you yank it out , strip off the injectors and turbocharger then toss it open ports down into some loose sandy dirt like in Pic. # 2 *8-| rolling eyes . notice they removed the top of the ALDA device on the recently rebuilt (!$!) injection pump , ruining it .

Make sure to leave behind all five of the brandy new injector heat shields as boob Nate might chance along soon and need some (pic. # 3)

Come home and clean every thing HOSPITAL CLEAN , install all the heat shields and fuel injectors making sure (for once) to use a properly calibrated American made torque wrench and tighten them all up to 75 Lb. Ft. per spec.

Before restarting the engine , take a moment to replace the one air cleaner rubber mount that broke even though you're pretty sure you replaced all three less than a MONTH ago *:-&lt sigh.

As long as the air cleaner and big black "U " tube is off , sick your fingers in to check the accumulation of oil in the intake stream and smile when you see there _isn't_ any , spin the turbo to gauge it's drag and to check the radial and axial free play , groan when you see it's _seized_ in spite of being fine and dandy yesterday when you shut it off *X( angry.

Grab a tool and try to force it to turn in case it's just bound up or dragging a little bit , be seriously pissed off when you discover it's as tight as a bull's butt in flytime *~X( at wits' end .

Not even freeway speeds and high RPM's will make it spin whatsoever *:( sad .

Looks like to - morrow's job is to go back to the Junk Yard and buy the non EGR manifolds I was looking at and find where I stored my spare , non rebuilt turbocharger , tear it all down again and try the spare turbo .

At least the new injectors all seem to work O.K. , no boost means way reduced power but it seems to idle smoothly enough and starts easily .

Pic. # 4 shows the importance of good Supervision .

-Nate



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Re: [diesel_mercedes] Oops

 

You use shims of various thicknesses to adjust the pop pressure, or just test other injectors you've picked up until you have all good ones to use. If you take it apart, you need to lap the surfaces, as well as re-shim, re-test.

Rob
Garden Grove, CA
=

On 6/5/16 10:49 AM, Max temple jasperezra@gmail.com [diesel_mercedes] wrote:
So............, you adjust the pressure by adding or removing shims? Then re-test till you get it within specs?  Are they different thickness? On China Diesel all you did was turn a screw. Max

On Sat, Jun 4, 2016 at 8:04 PM, Nate vwnate1@yahoo.com [diesel_mercedes] <diesel_mercedes@yahoogroups.com> wrote:



It's interesting what one learns by just doing the job .

1984 300CD

To - day's plan was to do a compression test , removing all five injectors and replacing them with recently pop tested ones and try to check the Injection Pump timing .

I discovered the # 5 injector's nose was soaking wet with Diesel fuel ~ this is (I think) a good thing because I'm still having exhaust smoking and minor spitting of raw fuel droplets out the exhaust , they fly back and splatter the recently washed and waxed Cove and Deck lid , sorely vexing me .

The compression test is fine although not as even as I'd hoped considering this engine was rebuilt about 35,000 miles ago .

#1 420 #

#2 420

#3 380

#4 400

#5 380

I removed the compression tester and cleaned up the oil that dribbled down from the open oil filler (oops) , filled the open injector well then pooled in the # 1 cylinder ~ when you crank the engine sans injectors and a bit of oil drools into one cylinder , it blows out in an impressive fog and spray of tiny droplets that covers every thing under the hood including the sound deadening pad , both front fenders , some of the windshield , the radiator and of course , the hapless fool who's standing over by the battery jumping the starter connections *:-B nerd . (hey ~ who wants rusty hair ?) .

I was working from back to front so I decided to do # 1 cylinder last and only after I laboriously cleaned all the oil collected in the threads in the injector well .

I also wisely decided to remove the heat shield because I was concerned oil might be pooled up under it and forcing oil droplets into a compression gauge is a good way to explode it in your (my) face */:) raised eyebrows .

Of course , I then decided to remove and clean up all the other heat shields and discovered another important thing :

Although it isn't mentioned anywhere , you're supposed to remove the heat shields _before_ installing the compression tester adapter as it seals by bottoming out and ruining said heat shields .

Oops (again , there's a pattern here I think) .

Did I mention it was beastly hot to - day ? .

There I was : all done and ready to install my five fresh non drooling injectors and go for a nice test drive but no ~ they cannot be installed sans heat shields and there's no place to buy them @ 6PM Saturday afternoon *:-w waiting .

So , I worked up a traveling  tool bag and rolled out my Motocycle and rode it here to the free WiFi spot , I'll check the local OnLine Junk Yards for Mercedes Diesels and head over to the one with the most of them to - morrow morning as I'm far from any of my other running (THREE more dead ones 10' from my now dead Mercedes) vehicles , buy a bunch more used fuel injectors tp lay with and grab some heat shields.......

But Nate I hear you ask , what about the I.P. timing ? ~ isn't it easier to do when all five injectors are out ? .

Yes Grasshopper , you're quite correct but no matter where I positioned the engine I couldn't get it to make any difference in how many drops dripped out of the timing tool so that's on hold .

At least I should have it running to - morrow on much less smoke and hopefully no more spitting out the exhaust pipe .

After  all the used injectors I've bought , you'd think I'd have a bag full of good used , cleaned and ready to go heat shields but for some inexplicable reason I don't know , I didn't grab any .

Stay tuned , more hilarity (?) to come .

Of course , no one close by is available to drive me to the Junk Yard to - morrow so I'll go on my Moto , tool bag hanging on my chest . cane and gloves etc....

Pay attention here and learn from MY mistakes *;) winking .

-Nate




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Posted by: Aleph93 <aleph93@ca.rr.com>
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Re: [diesel_mercedes] Oops

 

So............, you adjust the pressure by adding or removing shims? Then re-test till you get it within specs?  Are they different thickness? On China Diesel all you did was turn a screw. Max

On Sat, Jun 4, 2016 at 8:04 PM, Nate vwnate1@yahoo.com [diesel_mercedes] <diesel_mercedes@yahoogroups.com> wrote:



It's interesting what one learns by just doing the job .

1984 300CD

To - day's plan was to do a compression test , removing all five injectors and replacing them with recently pop tested ones and try to check the Injection Pump timing .

I discovered the # 5 injector's nose was soaking wet with Diesel fuel ~ this is (I think) a good thing because I'm still having exhaust smoking and minor spitting of raw fuel droplets out the exhaust , they fly back and splatter the recently washed and waxed Cove and Deck lid , sorely vexing me .

The compression test is fine although not as even as I'd hoped considering this engine was rebuilt about 35,000 miles ago .

#1 420 #

#2 420

#3 380

#4 400

#5 380

I removed the compression tester and cleaned up the oil that dribbled down from the open oil filler (oops) , filled the open injector well then pooled in the # 1 cylinder ~ when you crank the engine sans injectors and a bit of oil drools into one cylinder , it blows out in an impressive fog and spray of tiny droplets that covers every thing under the hood including the sound deadening pad , both front fenders , some of the windshield , the radiator and of course , the hapless fool who's standing over by the battery jumping the starter connections *:-B nerd . (hey ~ who wants rusty hair ?) .

I was working from back to front so I decided to do # 1 cylinder last and only after I laboriously cleaned all the oil collected in the threads in the injector well .

I also wisely decided to remove the heat shield because I was concerned oil might be pooled up under it and forcing oil droplets into a compression gauge is a good way to explode it in your (my) face */:) raised eyebrows .

Of course , I then decided to remove and clean up all the other heat shields and discovered another important thing :

Although it isn't mentioned anywhere , you're supposed to remove the heat shields _before_ installing the compression tester adapter as it seals by bottoming out and ruining said heat shields .

Oops (again , there's a pattern here I think) .

Did I mention it was beastly hot to - day ? .

There I was : all done and ready to install my five fresh non drooling injectors and go for a nice test drive but no ~ they cannot be installed sans heat shields and there's no place to buy them @ 6PM Saturday afternoon *:-w waiting .

So , I worked up a traveling  tool bag and rolled out my Motocycle and rode it here to the free WiFi spot , I'll check the local OnLine Junk Yards for Mercedes Diesels and head over to the one with the most of them to - morrow morning as I'm far from any of my other running (THREE more dead ones 10' from my now dead Mercedes) vehicles , buy a bunch more used fuel injectors tp lay with and grab some heat shields.......

But Nate I hear you ask , what about the I.P. timing ? ~ isn't it easier to do when all five injectors are out ? .

Yes Grasshopper , you're quite correct but no matter where I positioned the engine I couldn't get it to make any difference in how many drops dripped out of the timing tool so that's on hold .

At least I should have it running to - morrow on much less smoke and hopefully no more spitting out the exhaust pipe .

After  all the used injectors I've bought , you'd think I'd have a bag full of good used , cleaned and ready to go heat shields but for some inexplicable reason I don't know , I didn't grab any .

Stay tuned , more hilarity (?) to come .

Of course , no one close by is available to drive me to the Junk Yard to - morrow so I'll go on my Moto , tool bag hanging on my chest . cane and gloves etc....

Pay attention here and learn from MY mistakes *;) winking .

-Nate



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Posted by: Max temple <jasperezra@gmail.com>
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.

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