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  #61  
Old 07-12-2011, 09:47 PM
wildest's Avatar
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What the FSM says about injector cleaning:

http://mercedes.thatchermathias.com/Index/617T/07MechElec.htm

Look at part 07.1-135
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  #62  
Old 07-12-2011, 11:30 PM
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FSM

Quote:
Originally Posted by tangofox007 View Post
What does the FSM say about lapping the internal parts?
Interestingly, FSM (07.1-232) "Reconditioning injectors" says only "Dress intermediate disc (33) on a surface plate." It says nothing about the surfaces that have to mate with the two sides of the intermediate disk; it says nothing about performing this operation wet or dry; it says nothing about flatness or smoothness requirements of this "surface plate." [Note that the spelling 'disc' is literally what is in FSM.]

Another interesting thing is that my copy of the FSM ("Service Manual / Diesel Engines 602, 603" S-2517-091 published by Mercedes-Benz of North America in 1991) has two sections numbered 07.1. One is for NA diesels and the other is for turbodiesels. The sections are mostly the same but the writing (or the translations) differ slightly in content and wording, not only for the obvious areas of difference between a normally-aspirated and turbocharged diesel engine, but for areas that should be identical, such as the injectors. On top of that, the page numbers are identical and you cannot immediately tell whether you are in the NA or turbo section unless you happen to spot the "turbodiesel" in the chapter title.

Thus, the NA version of 07.1 "Diesel Injection System" has a section 232 "Reconditioning injectors" while the turbo version of 07.1 "Diesel Injection System - Turbodiesel Engines" also has a section 232 "Reconditioning injectors (after testing) - Turbodiesel." The sections are similar but not identical, for example, the NA version has information on cleaning the little holes that some needles have in their tips but the turbo version does not. Does this mean that NA diesels have holes in their injector needles but turbodiesels do not? [FYI, about these needle holes, FSM says longditudinal bores are to be cleaned with a 0.18 mm needle while transverse bores are to be cleaned with a 0.35 mm needle.]

Pardon the digression, which I use as warning that you must be cautious accessing technical service information, even when your source is a factory manual. Continuing, the NA version of 07.1-232 on lapping the internal parts says "Polish intermediate plate (33) on both sides on the surface plate." Is there a difference between "dress" and "polish" or were the two different versions of section 0.7.1 simply subbed out to two different translators? Examination of a German version of the manual would be educational.

So there's nothing explicitly said in FSM about polishing too much off of the parts and changing the pop pressure. However, FSM covers its corporate tail by listing "test injector" as the very last item in the checklist.

Jeremy
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Last edited by Jeremy5848; 07-12-2011 at 11:56 PM.
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  #63  
Old 07-12-2011, 11:47 PM
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Quote:
Originally Posted by Jeremy5848 View Post
Does this mean that NA diesels have hole in their injector needles but turbodiesels do not?
No.

Quote:
Originally Posted by Jeremy5848 View Post
However, FSM covers its corporate tail by listing "test injector" as the very last item in the checklist.
Anyone who thinks that you can reliably get away with cleaning nozzles and not testing them hasn't cleaned or tested many injectors.
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  #64  
Old 07-12-2011, 11:58 PM
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Considering that the local diesel shop in my town charges $45 each [plus parts!] to clean, test, and adjust injectors, a tester would be a good investment.
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"Buster" in the '95

Our all-biodiesel family
1995 E300D (W124) . .239,000 miles My car
1996 E300D (W210) . .313,000 miles Wife's car
Santa Rosa population 170,685 (2012)
Total. . . . . . . . . . . . 722,685
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970
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  #65  
Old 07-13-2011, 12:35 AM
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I have been thinking to buy a mercedes source kit, what do you guys think?



This kit includes the following:

Bench mounted hand operated injector release and balance tester to 3000 psi
24 piece shim washer assortment that allows you to precisely adjust the injector release "pop" pressure
Special brass tools to help clean the carbon of the tips of your injectors
Pick tool to aid in removal of injector heat shield washers
Assortment of medium to super fine lapping paper to prevent injector fluid leaks
Nitrile gloves to save your hands
Bolts and nuts to mount tester to work bench
Complete step by step illustrated instruction manual.
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  #66  
Old 07-13-2011, 12:50 AM
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Quote:
Originally Posted by scottmcphee View Post
Rebuilding is easy, done that. I have a pop tester.

Cleaning is what I was asking about.
When I took mine apart for cleaning and re-balanced them they needed chagnes to re-balance them.
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  #67  
Old 07-13-2011, 01:04 AM
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Quote:
Originally Posted by 1980-300D(bio) View Post
I have been thinking to buy a mercedes source kit, what do you guys think?



This kit includes the following:

Bench mounted hand operated injector release and balance tester to 3000 psi
24 piece shim washer assortment that allows you to precisely adjust the injector release "pop" pressure
Special brass tools to help clean the carbon of the tips of your injectors
Pick tool to aid in removal of injector heat shield washers
Assortment of medium to super fine lapping paper to prevent injector fluid leaks
Nitrile gloves to save your hands
Bolts and nuts to mount tester to work bench
Complete step by step illustrated instruction manual.
This is what I have. It works great! I mounted the pump on a piece of steel plate bolted to a 8" x 16" x 2" piece of wood. I don't use biodiesel for the tester because I am worried about bacteria growing in the pop tester when it is not in use.

You really need to use a respirator and goggles when using the tester otherwise you will breathe a lot of diesel vapors and you might get some in your eyes.

There is also an injector cleaning kit you can get from them that is helpful.
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Last edited by Bob Albrecht; 07-13-2011 at 01:06 AM. Reason: more info
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  #68  
Old 07-13-2011, 05:31 PM
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Quote:
Originally Posted by Bob Albrecht View Post
You really need to use a respirator and goggles when using the tester otherwise you will breathe a lot of diesel vapors and you might get some in your eyes.
Puts hair on your chest.
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  #69  
Old 07-13-2011, 06:11 PM
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Quote:
Originally Posted by 1980-300D(bio) View Post
I have been thinking to buy a mercedes source kit, what do you guys think?



This kit includes the following:

Bench mounted hand operated injector release and balance tester to 3000 psi
24 piece shim washer assortment that allows you to precisely adjust the injector release "pop" pressure
Special brass tools to help clean the carbon of the tips of your injectors
Pick tool to aid in removal of injector heat shield washers
Assortment of medium to super fine lapping paper to prevent injector fluid leaks
Nitrile gloves to save your hands
Bolts and nuts to mount tester to work bench
Complete step by step illustrated instruction manual.
Looks nice. Was kostet das? (What does it cost?)
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Last edited by RML; 07-14-2011 at 12:06 PM.
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  #70  
Old 07-14-2011, 12:09 PM
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Found it. $234.
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84 300D 331K Black (Rufus) 0-60 in 14 seconds (adjusted the ALDA)
00 Toyota Sienna 208K (Sold)
15 Subaru Outback 22K
98 Ford Taurus 62K (Gertie - Was Grandma's - drove it to church and shopping - really) Daughter's car now.
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  #71  
Old 07-15-2011, 04:55 PM
1980-300D(bio)'s Avatar
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Quote:
Originally Posted by RML View Post
Found it. $234.
Is it worth the price?

I guess I will test with the fuel I use, B100. I could run some LM purge after use if I'm nervous about the B100 monsters that can grow in it.
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  #72  
Old 11-20-2011, 06:37 PM
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I recently purchased the kit and would recommend that people by an entire set of shims instead of the small kit. I ended up having to take one of the largest shims and filing it down a few thousandths in order to balance out my six injectors. The kit would be improved if it came with the cleaning kit that Mercedes source sells. I didn't by it and ended up needing a brass brush and they are hard to find. I did have a bronze brush that I use to clean my 12 gauge and that worked perfectly. One of my injectors had so much carbon on it it was very difficult to clean.
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  #73  
Old 06-09-2012, 05:30 PM
home of 4,5,6,8 cylinders
 
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I cleaned out my injectors by running with high concentration Lucas fuel inj cleaners.
I messed her up when using filtered used motor oil!
Now i dont touch that stuff anymore.
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  #74  
Old 11-13-2012, 06:21 PM
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Thanks for DIY helped a lot. I did my OM606.962 and it is very similar.
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  #75  
Old 11-13-2012, 06:47 PM
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A diesel shop rebuilt my original injectors for about $60/each with new 115bar BOSCH nozzles, and all were balanced within 1bar of each other.

Just another option if you're not in the tinkering, injecting yourself with diesel @ 115bar and special tool buying spirit.
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