PeachParts Mercedes-Benz Forum

PeachParts Mercedes-Benz Forum (http://www.peachparts.com/shopforum/)
-   Diesel Discussion (http://www.peachparts.com/shopforum/diesel-discussion/)
-   -   OM606 engine wobble (http://www.peachparts.com/shopforum/diesel-discussion/394807-om606-engine-wobble.html)

spock505 08-24-2018 11:46 AM

OM606 engine wobble
 
Don't hold out much hope for finding out the issue but here goes, engine has a noticeable wobble at idle - this has been present since I bought the car but much improved, what' has been done to help, so far:

- New engine mounts, Meyle

- Two sets of injectors

- Replaced head, timed up correctly using gauge, re-set timing peg

- Tank flush

- New DV's

- Replaced O rings, filter several times

Out of interest today, pulled the main harness cable connector - revs dropped but wobble still present, hopefully this video shows fault better (cable plugged back in)

https://youtu.be/Gabu-rNVClo

Diseasel300 08-24-2018 11:58 AM

Your video link doesn't work, at least not for me.

You don't mention compression. Low compression on one cylinder or a problem with fuel injection on one cylinder will cause a lopey idle.

spock505 08-24-2018 12:02 PM

Yup, good point, comp test done prior to head swap, all good - bores were also in good shape on inspection, no blue smoke or blow-by at present.

Can you try link again, edited settings

Diseasel300 08-24-2018 12:10 PM

Works now.

The 603 in my SDL rocks a bit at idle too and I've not yet narrowed down the primary cause (it isn't compression in my case). It comes and goes, sometimes smooth as glass, others a bit wobbly. I suspect a valve that's not seating properly, an injector that's hanging up under certain operating conditions, or wear in the IP. Off-idle it's smooth and makes good power and economy, very low blow-by, but moderate oil consumption from a trashed turbo seal.

spock505 08-24-2018 12:30 PM

That's pretty much how this is, sometimes hard to detect and a little worse when hot.

Its most noticeable at sitting at lights, or when you are stationary with drivers door open, the edge really accentuates the rocking movement.

Couple of times after an 'Italian tune-up' went altogether, well at least for a few minutes.

Last time I did the DV's I noticed what looked like residue on the surface of plunger, (this is the bit that sits way down inside pump) so today pulled 5/6 out, plungers too - my intention was to swap out with OM606.962 parts which I had to hand, unfortunately all the part numbers were different so didn't risk it.

The plunger did have small build up but this looked worse than it actually was due to locating notch running up one side, from the top it could be mistaken for pitting.

Carefully re-assembled 5/6 torqued 35nm, engine eventually fired - exactly the same, no difference whatsoever.

It's getting quite sad now as not only do I know all the socket/spanner sizes, but torque values too, the above including manifold removal probably took less than two hours :o

spock505 08-24-2018 12:44 PM

Perhaps there's an idle sensor which is faulty hence unplugging main loom didn't achieve anything?

Diseasel300 08-24-2018 12:49 PM

If this is the 124 vehicle, it should be a mechanical IP with the EDS solenoid on the back just like the 603's had. If so, the EDS solenoid only adjusts idle speed, not unlike the idle speed plunger on old carbureted cars with A/C. Idle speed and operation is entirely mechanical, so no sensor can have any effect on how the IP runs. At idle, the ADA (or ALDA on turbos) isn't even in the circuit so it all comes down to how the IP is tuned internally. That's why I suspect IP wear in my case, especially given the rough history of even getting a working IP in my car.

spock505 08-24-2018 01:04 PM

That makes sense, thanks -

I did notice some pitting around where the copper washer sits, this was the other reason for wanting to swap out with 962 bits which looked identical.

..back to the drawing board as they say...

pimpernell 08-24-2018 01:21 PM

Quote:

Originally Posted by spock505 (Post 3838802)
That makes sense, thanks -

I did notice some pitting around where the copper washer sits, this was the other reason for wanting to swap out with 962 bits which looked identical.

..back to the drawing board as they say...




This thread gave me a lot of incite when I did my delivery valves. Might be some information that can be of help. Good luck!!







http://www.peachparts.com/shopforum/diesel-discussion/211801-om606-engine-w210-e300d-td-delivery-valve-seals.html

spock505 08-24-2018 03:56 PM

Thanks, but already changed DV's a while back, this time was to replace parts which looked a bit suspect.

Had a quick search for this issue, not much but did find this - something I would never have looked for.

Quote:

Originally Posted by weisskasten (Post 2919388)
Hi
Yes problem solved. There was a hairline crack in one delivery valve housing. I discovered it when I pulled them out to check. Upon retorqueing, it cracked in half. Apparently when it warmed up the crack would worsen? Anyway, a new valve has been installed. I had to then change the motor mounts(shot), and the belt tensioner(also ruined from bad motor mounts) Now it is so quiet and smooth. Wow!!!!

Also, does anyone know if these are part numbers indicating differences between OM606.910 and 962, they look identical ?

https://s25.postimg.cc/jxtggszzj/IMG_4451.jpg

https://s25.postimg.cc/ad9ttwni7/IMG_4450.jpg

https://s25.postimg.cc/hrz5mvh9r/IMG_4449.jpg

spock505 08-25-2018 07:57 AM

Re-visited this again today after watching this video, it really shows the importance of having correct height of holder (screw in bit) - although this is an earlier pump the principals are similar, here the adjustment is carried out using rotating plates held either side by bolts.

https://www.youtube.com/watch?v=uNn_Ko5dsDM

On later pumps such as mine there is no such adjustment but correct torquing must be critical, with this in mind I went back to check torque as undoing always seems way too difficult.

Marked random injector holder with pump body, unscrewed then re-torqued - it was within 1mm of original setting so didn't bother with rest, unlikely I would have changed torque wrench between holders.

I had considered the possibility of accidentally setting the wrench to pounds giving around 45 nm, but this wasn't the case.

Whilst in tinkering mode my attention turned to the altitude sensor, this has always been of some concern as it was badly bent to one side by previous owner/mechanic - although now straightened and vac tested never 100% sure, decided to drop the mixture down by screwing in the adjustment (original position marked) - this did nothing for the wobble but did improve the overall running, slight change the engine note under high revs which is quite pleasing -

Its running great and pulls like a train, going to leave alone before I break something heading into winter :rolleyes:

TMAllison 08-25-2018 02:27 PM

Has the trans mount ever been replaced?

spock505 08-25-2018 02:51 PM

Still original, removed a few times, visual inspection seemed okay but could be wrong.

Everything else (engine mounts, rear/front wheel bearings, control arms) needed replacing though, would this cause a wobble at tickover?

Texasgeezer 08-25-2018 05:27 PM

To spock505,

In your third photo yesterday, ( probably just my old eyes and the shadows ), it looks like the burnished area of the copper washer is thinner where the shadow is ( about the 6:20 ) position. Also the burnished area between the 8 & 9 o'clock position appears to be a little thinner. If the burnished area is thinner, then the seating is probably not uniform for that delivery valve position.

I guess the shadow might make it look like un-burnished copper in the photo, but the color appears to be the same as the outer edge of the copper washer.

About six months ago I changed my motor mounts and delivery valve copper washers and o-rings during the same session. After it was all back together I had more of a rough shaking idle than before. Luckily with a few weeks driving it smoothed out. Don't know if it was the motor mounts settling in or the delivery valves sealing better. I did decide that I would slightly polish the copper washers the next time I replace them. This is because, visually, the surface of the new copper washers did not appear to be as smooth as they could be. I thought that if they weren't uniformly smooth then they might not seal properly. (I tend to overthink things, so I'm probably being too concerned.)

spock505 08-25-2018 05:55 PM

Texasgeezer, spot on, there are different areas of burnishing which is something I looked at closely using an eye glass.

Here's the thing though, working out how these operate starts to whittle down my previous understanding, originally I thought the copper washer played some part in sealing the valve during pressurized delivery of fuel via injector, however this is not possible - let me explain why..

The copper washer in previous pumps is shown further down the assembly and not at the top, my guess is both copper washers are in fact 'crush' washers to ensure correct internal measurement when torqued.

Secondly, if you remove the two parts below the washer and measure inside the holder they cannot move anyway, once torqued down that's it - very snug fit.

My guess is the small pistons referred to in the video sit inside the sleeve pushing through the core ejecting X shaped spindle, this is the only part that is free to move and return back under spring pressure.

Careful observation of the sleeve show no vertical wear marks further confirming this theory.

That doesn't mean the copper washers are not important, they are to allow proper seating of internal sleeve parts, so this leaves one question - why the mirrored polished mating surfaces?

Two possibilities, firstly to allow centralization and alignment during assemble and operation, and also to accommodate any sideways vibration attributed to piston motion.

TM, ordered part number 124 240 0618

Cheers

spock505 08-25-2018 06:27 PM

If we look at the assembled parts outside of pump to gauge overall size, the copper washer sits a few millimeters below top of pump when housing is removed.



https://s25.postimg.cc/olmxyvsen/IMG_4452.jpg

The copper seal seats internally around where the rubber O ring is outside.

https://s25.postimg.cc/9cx0l3r0f/IMG_4453.jpg

The next piece shown below is fixed being anchored by a slot. Calculating distance from here until the copper seal face indicates they are held in situ, this part i believe is a piston sleeve.

https://s25.postimg.cc/o8vjsppkf/IMG_4454.jpg

Looking from below this is a very smooth bore like surface for piston travel, the exit hole sits beneath the tail of X piece.

https://s25.postimg.cc/qq7azz1r3/IMG_4455.jpg

vwnate1 08-25-2018 09:09 PM

Lopy Idle
 
Thanx for this detailed thread .

My 1984 300CD (OM617 - T) has an ever so slight loping at idle, I've replaced injectors and fitted all new delivery valves, no change .

I'll keep reading what ever you post on this and try it as it drives me bonkers, no one else seems to notice it (my fat jiggles at longer red lights) and SWMBO even commented how smoothly the car is running lately .

spock505 08-26-2018 08:11 AM

No problem Nate, makes a lot more sense now. Incidentally this pump design was used by Bosch for many years across numerous applications, lorries, cars all sorts, plenty of info but not all relating to our exact model of pump.

The other thing worth pointing out is naming of parts, in particular the 'piston sleeve' and 'piston', both of these seem to be collectively referred to as 'elements' especially by the super turbo forums, anyway on to our set-ups and what could be causing these issues.

Copper crush washer

There are three areas of possible failure (probably more) within this set-up, first lets look at the copper crush washer and what it actually does. It's important to note this is the only form of calibration within the set-up itself, once the splined holder is removed that's it, any factory settings are gone - the various videos and poster comments about factory settings being disturbed beyond this point is incorrect imo, once torqued down the crush washer acts upon the components withing the two yellow lines, the yellow arrow indicates fuel intake above the piston.

https://s25.postimg.cc/z3m6m4v5r/IMG_4453.jpg

This gap is absolutely critical as too tight (over torqued) and the mirrored surface parts will fail to move, too loose (re-using copper washer, re-torquing in my case) and fuel will seep past allowing pressure to dwindle from 'hydraulic lock' (see below)

the copper washer also serves a second equally important function, that is to seal the top portion between the DV (small part in center with X shaped protrusion) and injection nozzle, this creates a hydraulic lock'between the two parts - if fuel seeps past in this way it could create poor starting, timing issues, lack of fuel delivery and so on - my attempts at purchasing DV seals from my dealer hasn't been confidence inspiring, "I think these are the ones" - so next time out comes micrometer.

Regarding the mirrored surface, I don't think this has anything to do with piston as it remains vertical (no small end) during it's entire stroke, most likely just to ensure correct centering during assembly.

If your reading these posts you should know how important cleanliness is, also please do not pull your pump apart following my babble, these are still high precision parts which need a great deal of care when handling.

I'll put posts up separately on the other two areas mentioned with pics.

Texasgeezer 08-26-2018 10:44 AM

I entered a new topic a few minutes ago listing a site that covers some Bosch injection pump topics. One of them:

Bosch Injection Pump Delivery Valves | Diesel Engine Troubleshooting

http://www.dieselmotors.info/fuel-systems/diesel-engine-delivery-valves.html

Back to your 'wobble', after reading about delivery valves & pump return valve function, I was wondering if you replaced the springs for the delivery valves. It seems if one or more was weak it might have some impact on fuel delivery since the spring helps the valve seat quickly and firmly.

spock505 08-26-2018 10:55 AM

Okay, onto the second area of focus, the delivery valve itself and holder.

Delivery valve

https://s25.postimg.cc/sm3a2qne7/IMG_4460.jpg

https://s25.postimg.cc/x7zeb3w2n/IMG_4464.jpg

(apologies for blurry photos, took several attempts to get these)

First photo shows the valve itself, this sits inside the core leading directly down through to piston top - piston rises with a measure of fuel, pop out this comes opening a volume of fuel to the chamber above activating injector nozzle, return is aided by the spring but also small amount of back flow on injector nozzle closure.

The critical part for functioning is the seal shown with two blue lines in second photo, if this is degraded fuel will seep back overnight allowing the fuel to flow back.

Something to explore, if pitted it may be possible to hone surfaces as with head valves - not sure - please note, these parts are weighted and matched

spock505 08-26-2018 11:00 AM

Texas, nice one, and yes agree about the spring part, going to order full set from Bosch using pump serial number with kit.

Diagram in your link shows open/close of DV

http://www.dieselmotors.info/wp-cont...very-valve.jpg

spock505 08-26-2018 11:20 AM

Third point of inspection, the sleeve or piston cylinder -

Unfortunately you cannot easily check for tolerance fit with piston itself as this is fixed by other means as yet unexplored, however visual inspection of tube would be possible as below.

https://s25.postimg.cc/irc4wfjf3/IMG_4467.jpg

Being immersed in fuel for most of its travel i would hope wear in minimal, that said i might be bit more concerned about low sulfur diesel now, lol

Lots of topics and debate about injector nozzle changes/selection, these DV's do same amount of work albeit outside of a hot combustion chamber but worth consideration imo.

Diseasel300 08-26-2018 11:31 AM

Before getting carried away reinventing the wheel with the DV's, read this thread:
http://www.peachparts.com/shopforum/diesel-discussion/363700-delivery-valve-internal-leak-cause-nailing-yes-no-maybe.html

Yes, it's long, but it has a lot of good information. If the DV has an issue, usually it shows up as nailing and can be quite loud. Basically it's a non-return valve. You get positive shutoff or you don't. If you don't, you tend to get nailing due to timing issues that arise from leakdown in the high pressure lines.

Texasgeezer 08-26-2018 11:31 AM

I think you could rig a simple test to check the delivery valve for fit/tightness/seal. Put a vacuum with gauge attached by tube to the bottom of the cylinder, coat the valve with some light weight oil, insert in cylinder, apply vacuum and watch gauge. The one(s) that leaked first/quickest would be the ones most likely to not have a good seal. Probably would want to repeat test to verify the problem one(s).

A better test would be to build a test jig, similar to injector testing, that would allow diesel to be put under pressure to check each delivery valve for leakage past it's seated position. That would be a more reliable test for each delivery valve's components.

The photo of the cylinder looks to show some major pitting and wear, what's it history?

spock505 08-26-2018 11:42 AM

Diesel, I have never seen this explained on threads before, having read dozens with all sorts of wild stories, some are recent too.

Texas, agreed on test, photo is poor - camera on auto focus bu bore is mirror finish giving that odd hue.

Bosch pump kit, parts included in purple (no spring)

ebay listing number:172718447948

https://i.ebayimg.com/images/g/SeMAA...ID/s-l1600.jpg

spock505 08-26-2018 06:57 PM

Closer inspection of the DV's from 962 shows how the seating area had been cut, the seat is slightly fatter towards the right of picture.

it may well be possible to hone these seats for better contact

https://s25.postimg.cc/oxmrues1b/side_wear.jpg

https://s25.postimg.cc/o83zi1jrx/side_wear2.jpg

Texasgeezer 08-27-2018 07:44 PM

Finally got through most of the thread that "D 300" referenced in post 23. It does make complete sense that careful polishing of the delivery valve & it's seat in the delivery valve holder ( DVH ) would improve engine smoothness if the valve was not sealing tightly. Really glad he tried that and had good results. It's simple, the delivery valve is not doing it's job if the seat is not fuel tight.

Can anyone explain what happens to the fuel if it goes past the copper washer seal area? Supposedly it's been proven that re-doing the copper seal can improve engine smoothness.

On the copper washer and the seal it makes, where does the fuel go if it gets past the copper washer due to it not making/having a good tight seal? To me, it either has to (1) go down past the DVH & up the threads past the rubber o-ring or (2) go down past & under the DVH to a lower pressure area.

If (1) then it looks like the injection pressure would be enough to blow the o-ring.

If (2) it looks like the injection pump plunger would still be putting high pressure fuel at the bottom of the DVH. That plunger doesn't go up into the DVH does it?

Also if fuel is flowing under the DVH under high pressure it looks like that high pressure would cause 'cavitation type' wear of the DVH and the seat that the DVH sits on.

Sorry I'm dense on this but I haven't been able to find out why the engine would have a rough idle if the copper washer doesn't have a good seal. Where does the bypassing fuel go?

Diseasel300 08-27-2018 09:12 PM

The bypassing fuel from the copper washer goes down around the outside of the delivery valve and down into the fuel gallery. The whole "guts" of the injection plunger area is the fuel gallery, so any overflow goes right back down to where it came from. The pressure in that area is only 10-15PSI, so there's no risk of blowing out the O-ring.

An incorrectly seated copper crush washer causes leakdown exactly like a poorly seating delivery valve will. Since the injector line is below pop pressure, it has to pump up again before the injector will pop causing late timing, poor injection quantity, and noise.

spock505 08-28-2018 03:16 AM

Yup, spot on, it separates the high and low pressure areas of the system, it also keeps the barrel and delivery valve holder under load, failing this fuel would also exit under pressure from mirrored seal between barrel and DV holder.

Incidentally, i found out why those two surfaces have a ground mirrored finish, it's to allow the barrel to rotate increasing fuel flow into the piston area.

The piston (or plunger) itself has a helix cut into one side, the barrel fuel inlet (hole marked yellow arrow above) rotates inline exposing the opening for a longer duration, more fuel =

Texasgeezer 08-28-2018 01:00 PM

Is the reason for doing three torque cycles when installing the delivery valve assembly simply to improve the smoothness/tightness of the copper washer seal compressed surface area? ( Hopefully to result in a much better seal?)

Diseasel300 08-28-2018 01:09 PM

The multiple tighten/loosen cycle is to guarantee that the copper crush washer seats fully. Remember that it's resisting >2000PSI during an injection event. Doing the tightening in a single step doesn't allow for compression of the metal and will result in a poor seal.

spock505 08-28-2018 04:25 PM

I remember reading on one of the threads this procedure had been revised by MB to single torque, personally more comfortable with the former as makes more sense given delicate nature of set-up.

Waiting for my transmission mount to turn up, high hopes this at least might be a contributing factor, however comforted by the DV back-up now I have a better understanding of the workings.

I think you are either one of those people who accept and drive things or the other who like to pull things apart, putting yourself in the designers shoes thinking how can we make this work.

Back to the 962 v 910 parts issue, barrel and piston (elements?) is the parts swapped to increase fuel delivery, does anyone know if 962 and 910 are the same ?

I can measure both when out of pump but would be handy to know in advance.

spock505 09-03-2018 08:29 AM

Replaced transmission mount today, much anticipation as old one looked fine but rubber soft and pliable, virtually no absorption qualities left.


...and nope, still there but the mount needed doing anyway, possible reason for burning out three center bearings ..

Diseasel300 09-03-2018 09:52 AM

People like to claim that the engine and transmission mounts are there to prevent any engine vibrations from reaching the chassis. In part that's true, but they're not going to stop a rocking motion. The inertia from the heavy engine/transmission rocking back and forth WILL transmit to the chassis regardless of what kind of engine mount is used.

One question I've had that nobody seems to be able to answer is whether or not the M pump has any sort of a rack damper like the MW pumps did. If there's some sort of internal adjustment that could be made, that could be the answer. Like you I'm sort of out of explanations.....I have good compression, good injector spray pattern, no nailing, good power and economy, and smooth running except for that lopey idle that's present whether or not the EDS solenoid is energized.

spock505 09-03-2018 11:00 AM

Tend to agree on your first comment, not sure about second as no knowledge of either.

Just back from 30 mile round trip, wish I had changed this a while back as trans shift much improved and very smooth.

This is not one of those components you can easily check , visually they look identical until compressed, good post on MB.org describes this well and so true.

Back to the wobble, it's 'just' still there, almost to the point of leaving alone which I may well do. The most likely is a DV not sealing imo, either one of the crush washers or the DV valve seal itself.

This type of fault will escape normal detection using pop tester/spray pattern, if the valve cannot hold pressure timing issue,delayed opening or even partial opening late causing a 'pink' effect.

I was thinking of making a small bow to wrap around wooden dowel, drilled out to hold top of DV - will check earlier thread for your comments Diesel.

spock505 09-03-2018 11:11 AM

Thinking of it another way, the DV's are not balanced as you would expect from six injectors pop tested to within couple of bar - how do we know the DV's are performing equally well....this is one of my fist YouTube videos which surfaced on an unrelated Google search.

The story behind this was trying to establish when number one pot was on injection stroke, marked the aux belt with paint 15 degrees ATDC..


..hey, don't laff it worked ..:D

https://www.youtube.com/watch?v=SQ5KIgWatJk

One way to check your DV's..

Diseasel300 09-03-2018 11:34 AM

Not sure how that would test the DV's. The amount of leakage required to cause nailing is minuscule in comparison to the amount of fluid pumped by the pumping element, even at idle. If the DV's are worn so badly as to cause a dead-miss, you have more serious problems!

spock505 09-03-2018 11:56 AM

From what I understand about this design not all the pumped fuel makes into high pressure side, isn't there a bypass back into the galley via piston element?

I would be surprised if nailing is the only symptom of poor DV seal/s, the amount of fuel emitted at nozzle end is small, very small getting that balanced with the rest is quite a delicate operation - example, what about if over-torqued, the barrel element may not rotate smoothly, instead juddering.

Up until now there's been a general paranoia about touching anything below crush washer, not much written on subject in terms of solutions, btw, did you replace your crush washers after re-torquing each time?

On a couple of mine I didn't in fact no: 6 removed the other day has been torqued up 3 possibly 4 times using same washer, good place for me to start.

Diseasel300 09-03-2018 12:14 PM

The overflow port is part of the pumping element, not the delivery valve. The delivery valve is literally JUST a check valve. That's it! When the pressure is high enough to pop the injector, the DV unseats and the fuel flows in the hard line until the pumping event is complete (pumping element reaches the top of its stroke). At that point, pressure drops in the hard line, the DV re-seats (and creates a slight pressure drop in the line to ensure positive cutoff of the injector) and creates a liquid-tight seal to prevent the hard line from bleeding down.

All of the rotating and spilling is done in the barrel of the pumping element, which is before (below) the DV. The DV is literally the same concept as a check valve in a plumbing system. It allows fluid through one direction, but not the other. Instead of dealing with 30-100PSI of water mains, it's dealing with 2000+PSI in the injection system. Thinking of the DV as anything other than a high pressure check valve is overthinking the situation.

I've dealt with the crush washers too. I've reused some before, and I did get nailing - very loudly. Replacing them every time the holders are removed is an important step. They're cheap, just do it. Always replace the O-ring at the same time. I've also found it necessary to wipe the threads and O-ring with diesel fuel before insertion to get accurate torque - a step that's often left out of writeups.

spock505 09-03-2018 02:02 PM

..ta.. Diesel, good post - my mild disappointment has been somewhat overshadowed by the transmission improvement, that said getting the ''wobble' sorted however minor would be the icing ..

Forgot to take serial number off pump while tray removed, going to order full kit as per link above PLUS the contentious - springs - direct from MB.

With regard to copper washers, did you notice any change after they had been in use? - i ask as those on 962 were considerably thinner (worn?) then the newer 910 additions.

As mentioned before, the ordering process was a little hit and miss which always causes concern, especially after ordering those auto box valves.

reading the turbo forums, 962 uses 6mm elements often replaced by 7.5 or even 8mm - any idea what size 910 is for swap- ability ?

Diseasel300 09-03-2018 02:16 PM

I've gotten to the point that I ignore the lopey idle on mine. Nobody else seems to notice it and it only really gets annoying when sitting at long traffic lights. Sometimes it goes away entirely and the engine idles smooth as silk. Normally it's very soft, unobjectionable. Occasionally it's enough to be annoying and make the car jiggle, sometimes accompanied by minor nailing. One of these days I'll finally work out what it is and solve it, probably completely by accident.

The crush washers should be the same regardless of turbo or non-turbo. I've noticed no difference after use other than the "tractory" qualities quietening down after a few hundred miles of driving. I don't have tens of thousands of miles on mine yet, so I don't know long-term any sort of wear first hand.

Not sure on the pumping elements on the turbo vs n/a pumps either. I've read that all 601/2/3's used 5.5mm elements regardless of turbo or n/a. I know the 210's use 6mm elements, not sure about the 124's, but I'd expect them to be 6mm maybe? You could always measure the bore with a caliper to find out. Using a different size pumping element requires recalibrating the injection pump.

spock505 09-03-2018 02:51 PM

Here's my current thinking, bear in mind the video posted above with paint marker on aux belt.

I have six spare injector lines, six almost new injectors -

Proposed solution:

Mock up a similar rig to above video using spare injector line, encase injector inside 5 litre clear plastic bottle to observe spray pattern ...wait for it....


..when running, i.e pull one line at a time leaving everything else in place (5 other injectors) - this is not dissimilar to pop testing the injectors themselves, only difference is using a live rig -

It's clear during pop testing any deficiency so hopefully same lines here, if it throws up one odd pot then investigate in normal fashion..

Diseasel300 09-03-2018 08:04 PM

If the injector has a good spray pattern on the bench, it's gonna have a good spray pattern on the engine running, the delivery valves and pumping elements have no effect on spray pattern. The pattern is not what's important here anyway, it's the injection QUANTITY as well as the exact timing. You cannot accurately measure either one in your driveway, the IP would have to be pulled and put on a calibrated test rig to determine anything useful. By the time you did that, send the damn thing off for rebuild, it's only another hundred bucks or so at that point compared to the time and expense put into testing the IP.

spock505 09-04-2018 01:46 PM

You misunderstand, it's not about measuring but performing the same visual tasks as you would pop testing - lets see if all six match each other, if one is a bit out of sorts that could be suspect.

Most of pop testing is visual, checking chatter, spray pattern and so on - i know the injectors are good so any variance is pump side.

Thinking about it, this is a lot quicker than pulling all six holders, no priming either - just plug and play.

I have a small pipe bender for the job.

Diseasel300 09-04-2018 01:57 PM

Quote:

Originally Posted by spock505 (Post 3841400)
You misunderstand, it's not about measuring but performing the same visual tasks as you would pop testing - lets see if all six match each other, if one is a bit out of sorts that could be suspect.

Most of pop testing is visual, checking chatter, spray pattern and so on - i know the injectors are good so any variance is pump side.

My previous point still remains valid. If the injectors test good on the bench and have good pop and spray patterns, they'll do the same on the engine. If the IP develops enough pressure to pop them, it's going to be the same pattern they did on the bench. There is nothing in the IP that will affect pop pressure or pattern.

If the IP is ruined enough internally to be causing a dead-skip at idle, it should be easily identified by simply cracking the injector lines one at a time and finding the one that makes no difference.

If the IP is marginal on one cylinder, cracking the lines one at a time and finding the cylinder that makes the least amount of difference will identify the cylinder that needs further investigation pretty quickly.

dieselbenz1 09-04-2018 02:33 PM

Quote:

Originally Posted by spock505 (Post 3841400)
You misunderstand, it's not about measuring but performing the same visual tasks as you would pop testing - lets see if all six match each other, if one is a bit out of sorts that could be suspect.

Most of pop testing is visual, checking chatter, spray pattern and so on - i know the injectors are good so any variance is pump side.

Thinking about it, this is a lot quicker than pulling all six holders, no priming either - just plug and play.

I have a small pipe bender for the job.

Make certain to take a video and post it should you go ahead with this.

spock505 09-07-2018 06:10 PM

Couple of developments to report, firstly sent off pump serial number to listing above for compete match - need to order...perhaps..


As mentioned during summer month run 100% of veg oil which provides better lube and smoother operation, given this decided to add 500ml of alcohol per 60 litre of veg - cheap skate diesel purge idea ?

Without claiming a complete success, each journey is an improvement on the last, something to watch.

spock505 11-01-2018 05:19 PM

Wobble update +
 
Weather in upper part of hemisphere is starting to get chilly, earlier altitude sensor adjustments may have been a worked okay on tick-over but proved problematic when starting.

Anyhooo..reversed changes increasing fuel to air ratio (choke) - this device is fitted to compensate for high altitude where air density deceases/increases.

The purpose of my post is to ask whether this mechanism adds a 'dampening' effect similar to the old SU type carburetors?

There's no doubt it makes a difference to injector performance, just not sure exactly how.

spock505 03-28-2019 03:45 PM

Few bits and bobs ordered ready for pump overhaul, one thing to point out is this relates to pumps fitted to OM603. 5 and 6's which don't have torqued nozzle holders.

I point this out as there is much misinformation stemming from earlier pumps requiring more detailed calibration, just because someone made a YouTube video don't mean it's correct :P

spock505 03-30-2019 07:16 AM

Hopefully located the source of problem but likely need couple of small parts, return springs and so on -

Anyone point me in the direction of manual for M series Bosch pump, MW is available online for earlier models but not the latter M type.

Thanks,


All times are GMT -4. The time now is 02:22 AM.

Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2025, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0
Copyright 2024 Pelican Parts, LLC - Posts may be archived for display on the Peach Parts or Pelican Parts Website