Quote:
Originally Posted by dablk1
What's required to rebuild the injector nozzles?
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This is what was done were I used to work:
Customer brings in Injectors for rebuild; the Injectors are tested.
The reason for testing them is for troubleshooting purposes. You want to get the money for the rebuild but at the same time you want to build-up some "Good Faith" with the customer.
He may have pulled a good set of Injectors and his vehicle is actually haveing other problems.
As mentioned in a previous post Pluged Air Filters can caus smoking.
After testesting the Injectors (on a Diesel Nozzle/Pop Tester) are taken apart. However, the parts for each Injector are kept together. This makes it easier to adjust the Pop/Opening pressure when they are assembled and the 2 parts of Spray Nozzle part of the Injector cannot be mixed with other Spray Nozzles as they are mated together (you may be reusing the Spray Nozzles if they tested OK; it it is up to the customer). Of couse they are cleaned; chemically and sometimes with an ultrasonic cleaning tank.
After that the precision flat surfaces of the Injector are lapped on a Lapping Plate till they are flat againe and carefully clened off.
The Injectors are assembled (with new Spray Nozzles if that is what the customer wanted) and tested again. The Opening Pressures for each Injector are recorded.
If the Opening/Pop Pressures of the Injectors are not correct you need to change the shim/s inside of the Injector to put a different spring tension on the Spring. This sometimes requires taking the Injector apart several times till you get it right. (You measure the shims/s and compare it to the Opening Pressure and gestimate the next size shim you will need.)
When you are testing the Injectors you are looking for a good spray pattern, the Opening Pressure, leaks around the body of the Injector and you bring the pressure of the Injector to 200 psi below the opening pressure to see if the seating area leaks (you are allowed x number of drips per an amout of time).
When setting the opening pressures all of the Injector opening pressures must be within 5 bar when compared to each other. A private shope rebuilding the Injectors will try to get this as low as they can without spending too much time on them.
A good fast tech working with a complete set of Injectors can do the whole job in 10-15 minutes for each Injector.
I think there is a Do It Your Self thread somewhere on the above.