Diesel injector overhaul - illustrated
 

Go to my web site - Cars - Technical - Motor.

This simple job has a huge payback in terms of smoothness and reduced noise. It accomplishes what Diesel Purge cannot - a thorough cleaning of the injectors' components.

Thanks to Dave Meimann ('gsxr') for pointing out that scored bypass barbs can cause leaks. I cover this topic in the pictorial.

Enjoy!

You can clean diesel injectors by disassembling and keeping the parts together for each injector. Soak them in carburetor cleaner, not the spray or B12, but the caustic solution that is used to "boil out" carburetors.

Soak them in this solution overnight, then reassemble ensuring that parts are not interchanged from injector to injector.

Good luck,

Awesome site!!! I'll be bookmarking that one when I get home.

website fails
 

Every time I try to go to it via your link thomas it fails. I get the typical error for ... no such web site found.

Coach, try this..

http://www.pindelski.com/

It seems the website is really intermittent. I don't know if it's the hosting ISP, or the network in general in that part of the country. I sent the link to someone in PA, who could not access it, while I was surfing the site in ID simultaneously. Very weird. Keep trying, eventually you should get through. And yes, excellent information there!

:D :D

Are 603 injectors (dis)assembled similarly? Anything major that I should be aware of? Thanks!

Yep, 61x and 60x injectors are very similar. If they're not visibly dirty, it may be hard to tell if there's any improvement without a bench "pop" tester, which is really handy to test the spray pattern and also the break pressures, as well as leaking. Unfortunately they cost ~$200-$300. :( Make sure you have a VERY clean work area before messing with injector internals! The slightest bit of dirt can hang the pintle movement, and if that happens, it will sound like an angry little troll is wailing away at the inside of your engine block with a sledgehammer, at any speed above idle. VERY scary stuff. (Don't ask how I know this.) :eek: :eek:

Dave, How do you know that ?

You just HAD to ask, didn't ya. ;) Happened on my sister's OM603 when I removed the rear 3 lines to R&R the ALDA. Started the car back up and BANG BANG BANG! Scared me to death, and it wasn't going away. Cracked each injector line and found that with #4 loose, the noise vanished. Pulled that injector and tore it apart, found the pintle was locked solid. I mean I had to use a vise, pliers, and massive force to get it apart... normally slides in & out under it's own weight! Got it cleaned up & sliding better (not perfect) and it worked fine after that (amazingly enough). I never found the particle, but given the clearances involved it would be very, very small.

Awesome
 

Excellent Job - I am going to wear gloves as that stuff turned your hands blue!

Diesel injector overhaul - illustrated
Go to my web site - Cars - Technical - Motor.


thanks for the site and your efforts to put the info up for all to see. i have referred to it often.

TX76513
 

Yes, the lacquer thinner is nasty stuff. Watch your eyes too when using compressed air to dry the parts.

Gsxr is dead right on the fit - even with the hole in the end, it feels like a near perfect suction fit if you assemble dry, and a very precise sliding fit with WD40 in place. The whole thing leaves me thinking that a diesel injector at some $55 is a relative bargain to a gas one at $35. Leica fit and finish.

Gsxr - my hosting service is readyhosting.com and they have a very high 'up' time. I wonder whether the access difficulty some experience is caused by using non-Java script compatible browsers - my menu uses Java, or so I'm told. Also, some users with webTV have reported difficulty getting in. It seems OK to many in my family with either IE or Netscape, Apple or Msft.

83300DT - thanks for the support. Nice car, BTW.

When I hit the home page, I get a white screen to tiny boxes with red "X"'s in them and the menu in the middle. Works good enough for me, as that's where the goodies are anyway. :D

Great website!! Unfortunately for me, about a week too late. It cost me $105.00 at the good guy price to have my mechanic do the same thing as described on this site.