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  #1  
Old 01-11-2010, 03:40 PM
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Injector Nozzles

I just ordered some Monark replacement nozzles for my '92 300D, is a pop-off test required before installation in vehicle??

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  #2  
Old 01-11-2010, 03:51 PM
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For all practical purposes, yes. The probability that all injectors will be within specification is extremely low. I have replaced dozens of nozzle sets and have never had a single set test even close to spec prior to adjustment.

Even a set that is within +/- one bar with the original nozzles can be all over the board with new nozzles.
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  #3  
Old 01-11-2010, 04:25 PM
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I pop tested my old (original) injectors, and they were surprisingly not too badly off the mark. Only one was a low popper. Half of them had bad sprays as well.

I obtained a pop tester and shim kit with my Monarks, and set them all to top of range 145 bar. Plus or minus 10 psi kind of thing.

What surprised me was what little relationship there was to the previous nozzle in the injector to what its replacement needed to be shimmed at.

If all your previous nozzles were bang on, there is NO guarantee you'll be within spec on your new nozzles.

While they're out, it's so easy to do. Do it.
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  #4  
Old 01-11-2010, 04:51 PM
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FYI pop tester data.

Diesel injector nozzle POP test pump
http://www.peachparts.com/shopforum/general-information/213112-diesel-injector-nozzle-pop-test-pump.html#post1759285

How to build a diesel injector pop tester
How to build a diesel injector pop tester







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  #5  
Old 01-11-2010, 10:49 PM
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If you do not Lap the precision surfaces inside of the Injector there is a chance they will leak between the Nozzle Nut and the upper Body.

Red Arrows show the surfaces. The part with the double Arrows need both sides lapped.
Attached Thumbnails
Injector Nozzles-injector-apart-x.jpg  
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  #6  
Old 01-12-2010, 01:33 AM
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Quote:
Originally Posted by tstyler6 View Post
is a pop-off test required before installation in vehicle??
yes, always whenever anything inside the injector is changed.
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  #7  
Old 01-12-2010, 03:58 AM
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When CSEANWATTS installs new nozzles, does he pop-test them? I'm sure he does since he has such high ratings. He did a set for me about 8 months ago...
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  #8  
Old 01-12-2010, 05:05 AM
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I just got a new injector set from C sean Watts, they were all pop tested, Shipped nicely too in a nice padded container
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  #9  
Old 01-12-2010, 09:53 AM
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I believe I have read on this forum that C Sean Watts used to pop test new Monarks, and now does not anymore. He said that they are always right on from the factory.

I may be wrong, however.
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  #10  
Old 01-12-2010, 10:36 AM
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Quote:
Originally Posted by Diesel911 View Post
If you do not Lap the precision surfaces inside of the Injector there is a chance they will leak between the Nozzle Nut and the upper Body.

Red Arrows show the surfaces. The part with the double Arrows need both sides lapped.


Nah, Utter Rubbish!

Done hundreds of injector re-builds, its all in the Cleaning of ALL the parts and Exactly HOW you do the injector up on final assembly!!

--There is a Knack to it!
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  #11  
Old 01-12-2010, 11:51 AM
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Quote:
Originally Posted by 4thesporty View Post
I believe I have read on this forum that C Sean Watts used to pop test new Monarks, and now does not anymore. He said that they are always right on from the factory.

I may be wrong, however.
New nozzles and new injectors are two very different different concepts.
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  #12  
Old 01-12-2010, 05:35 PM
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Quote:
Originally Posted by Alastair View Post
Nah, Utter Rubbish!

Done hundreds of injector re-builds, its all in the Cleaning of ALL the parts and Exactly HOW you do the injector up on final assembly!!

--There is a Knack to it!
Cool!
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  #13  
Old 01-12-2010, 05:39 PM
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Quote:
Originally Posted by 4thesporty View Post
I believe I have read on this forum that C Sean Watts used to pop test new Monarks, and now does not anymore. He said that they are always right on from the factory.

I may be wrong, however.

C Sean Watts also sells completely new Monark Injectors. I believe those were the ones he was speaking of that are always righ on from the factory.

We PMed each other several months ago and on his rebuilds; besides Pop Testing he also laps those precision surfaces.
He also has an Ultrasonic Cleaning Tank.
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  #14  
Old 01-13-2010, 04:08 PM
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Quote:
Originally Posted by Diesel911 View Post
C Sean Watts also sells completely new Monark Injectors. I believe those were the ones he was speaking of that are always righ on from the factory.

We PMed each other several months ago and on his rebuilds; besides Pop Testing he also laps those precision surfaces.
He also has an Ultrasonic Cleaning Tank.
Yes, yes and thank you. I've been busy the past few weeks. NO manufacturer, I've ever heard of, makes nozzles (to be installed in injector bodies) that DO NOT need to be tested - did that make sense? All new nozzles installed should be pop tested when installed, regardless of make. Monark's NEW, ready to install complete injectors are set from the factory. I check them at random (about half) and none have ever been off. As for the servicing - I stick to MB's FSM, "Dress the surfaces {see red arrows in photo above} before reassembly." FWIW, this also applies to VW, Volvo and a fork lift I once worked on. For the benefit of any new folks, when we say, "lap" or "dress" we DO NOT mean removing measurable amounts of metal, leaving any new machining/sanding marks or rounding the edges in any way. Your objective should be leaving a shiny, clean mirror finish. Also, when we say, "clean" the injector parts we mean thoroughly, completely and as much like a NASA satellite assembly room as you can possibly get. It is not unreasonable to spend up to 30 minutes on ONE dirty injector.
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  #15  
Old 01-13-2010, 05:37 PM
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So what is an average price for 5 injectors ready to go into my 300sd? and did you guys see big improvements after changing these?

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