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  #1  
Old 06-12-2007, 09:23 AM
777funk's Avatar
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603 or 602 Injector nozzle change Leaks!!!!

I just changed the injector nozzles (new bosio nozzles installed in the original housings) on my 87 300d and they leak now. I don't know how to get the darn things to stop leaking fuel. The car idles smooth now with less pinging but start ups are rough due to the loss of prime because the injectors leak all the fuel in them when it sits.

Here are my leak areas and how do I fix them:

1. Injector body itself where the two pieces screw together

2. Injector where it screws into the prechamber (I see bubbling when the car is running around the circumference of the injector base).


I can't fix the leaks for anything. Any ideas.

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  #2  
Old 06-12-2007, 09:31 AM
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Also... are there supposed to be any O-rings in the injector housing? There were none when I disassembled but I saw them advertised at *************** so now I wonder.
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-E300d '99 350k
-Suburban '93 220k
-TDI Jetta '03 350k
Sold
-F250 '96 7.3
-Dodge Ram 12V
-E320 '95 200k
-E320 Wagon 1994 155k
-300d Turbo '87 187k miles
-E320 1994 200k
-300d Turbo '84 245k (sold to Dan62)
-300d Turbo '84 180k
-300sd '80 300k
-7.3 Powerstroke Diesel 15P Van 500k+ miles
-190d '89 Non Turbo 2.5 5cyl 240k (my first MB)
Tom's Imports of Columbia MO Ruined the IP in changing leaky delivery valve O-Rings - Refused to stand behind his work. Mid-MO MB drivers-AVOID Tom's.
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  #3  
Old 06-20-2007, 09:54 PM
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Join Date: May 2006
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Yo, the SAME exact thing happened to me last summer. Changed out old nozzles for Bosios, got the darned manifold back on (hardest part of the job), and found that every single injector leaked through the middle of the injector body, and at the base. The smell of baking diesel makes the car extremely undrivable. I posted here last year and no one could give me an answer, so my car has been sitting in the garage since last summer. I too would appreciate some insight here.

Perhaps they're not torqued down hard enough? Do you have to use some sort of thread sealant?
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  #4  
Old 06-21-2007, 08:52 AM
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I got most of them fixed. The heat sheilds I used were not the right ones. Some guy sold me 617 heat sheild with rings in the inside. I figured they were close to 603 shield and just put em in. The rings fell out somehow. Who knows where they went. But I wonder if they were out before I installed them. Hopefully. Anyways, if you:
1. Don't clean all the crud out of your injector body housing
2. Use new Properly installed heat shields (I recommend the new set I got from *************** they are black in color and only 1 piece and no ring).
3. Clean the seat in the prechamber so the heat shield makes a good seal.

Then the injectors shouldn't leak (as bad
Thanks,
Nick
__________________
-E300d '99 350k
-Suburban '93 220k
-TDI Jetta '03 350k
Sold
-F250 '96 7.3
-Dodge Ram 12V
-E320 '95 200k
-E320 Wagon 1994 155k
-300d Turbo '87 187k miles
-E320 1994 200k
-300d Turbo '84 245k (sold to Dan62)
-300d Turbo '84 180k
-300sd '80 300k
-7.3 Powerstroke Diesel 15P Van 500k+ miles
-190d '89 Non Turbo 2.5 5cyl 240k (my first MB)
Tom's Imports of Columbia MO Ruined the IP in changing leaky delivery valve O-Rings - Refused to stand behind his work. Mid-MO MB drivers-AVOID Tom's.
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  #5  
Old 06-21-2007, 09:55 AM
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you LOST THE HEAT SHIELDS??? ya mean INTO THE ENGINE?? uh, I would seriously look in the prechamber for debris! those things are not cheap, and not easy to install/remove/machine to fit!!
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  #6  
Old 06-21-2007, 12:00 PM
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I got my heat shields from Diesel Giant, and they were gold and included no rings or anything. They were just a one-piece assembly. 777funk, did this stop the leakage at the center of the injector? Or just at the base? I don't understand how it would stop leakage at the center. Also, how much leakage is there post-fix?

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