injection problem 603

[michael cole]

a recent attempt to reseal the delivery valves on my 603 has led me into some trouble.all was going well until i resealed #4 valve.now i have no injection thru that valve.i have tried retorqing the valve holder several times.i have opened it up several times to check for obstruction.al seems well but no injection.remarkable how well this car will run on five cylinders.idle is pretty rough though

I'm a little lost on what you are saying! Are you refering to the Bosch fuel injector as being resealed? Or are you referring to the intake valve having new seals?

BB

[michael cole]

actually i was referring to the delivery valves on top off the injection pump.they contain a copper seal and an oring both crucial for proper sealing of the injection pump.leaking seals here will cause poor running of the engine smoking and rough running.i was in the process of replacing them everything waas going great until i got to #4 delivery valve.im not getting any fuel delivery from that line

[Wasuchi]

How far have you run it? Are you sure it doesn't just have air in the line still?

[michael cole]

i have taken it for several highway runs and tried the usual bleeding methods to no avail.im now wondering if i may displaced something inside the pump when i removed the delivery valve

[Hatterasguy]

No there is no air in there, the 603's bleed themselves. It sounds like something got messed up. How do you know it is #4? Did you start the car after doing each one? I would go back and check all 6 just to make sure. Also make sure you torque them right.

[michael cole]

retorq was according to spec 30ftlbs i beleive.by loosening the union nut at #4 injector i can see there is no fuel delivery at this point.its dry.idle is rough and does not change when the union is loosened.i used a magnetic pick me up to remove the pressure valve components.just so i wouldnt drop them into the never never land of the skid pan.im thinking now that i may have somehow pulled up on the plunger assy and somehow dislodged it.

[Hatterasguy]

Ouch, maybe it is time to take the IP off and get it tested.

I wonder what Sixto and GSXR will have to say on this.

[gsxr]

That doesn't sound good. Did you use the 3-stage torque procedure outlined in the TDM? If not, I'd try that for starters...

[michael cole]

yes ive tried retorqing sevral times.im wondering if the plunger assy may have become dislodged.there is an access plate on the side of the pump.i could take a peek and see if everything looks to be in order.i know that the plunger and barrel assy can be pulled out thru the top of the pump.wish me luck

[michael cole]

problem partially solved.i removed the delivery valve and spring and tried running it that way.then replaced the valve and spring.now im getting fuel delivery to that cylinder verified by opening the line at the injector.however injection pressure still does not seem adequate to open the injector.i removed the injector and tested with my handy dandy bosch pop tester and it test good.im still running on 5cyl at idle.maybe ok at higher speed

[psfred]

Make sure the delivery valve is clean and that the copper ring isn't scored. In fact, I get another and replace it -- doesn't take much of a defect to cause it to leak down, which will give you no fuel at idle.

Also, make sure the delivery valve isn't in upside down and that the spring is OK and present.

You only need to watch that the spring and valve (the little steel thingy) don't get lost or dirty, you can lift the washer off with a bit of wire or a pick, no need to disturb anything else.

You may have lifted the sleeve off the rack if you picked it up with a magnet -- if so, I belive you can just re-install it making sure the pin fits in the rack correctly.

Peter

Peter

[michael cole]

im going to try again with another copper seal.i think your right it must be leaking pressure internally.