One of my injectors is seeping a little bit at the gray washer on the injector body. I am contemplating replacing it myself since I have access to a Bosch injector repair kit and injector tools. I am looking for feedback from anyone who has done this.

I have rebuilt some of the earlier injectors (300Ds, VW Rabbits). They were easy to do. First of all, I would make sure that the union on top is not the cause or a return line. The injector un-screws apart. Cleanliness is of the utmost importance when re-assembleing the injector. There are no seals internally and they depend on "lapped surfaces" to seal. I took a flat piece of glass, 400 grit wet or dry and wet lapped the larger components to make a good seal. Clean,clean,clean all parts with Diesel fuel and compressed air before you put it back together again. Assemble it with a small amount of Diesel fuel. I am not sure of the torque on the later injectors but the earlier ones torqued to 55ft lbs. A vice works good for this. Replace the heat shield also.

I had seeping on injector #4 of my 300D a while back. After I re-torque it and it's fine now. Becareful with those heatshields...they break easily. Dealers don't carry them anymore...

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BJ

09 GL320 Bluetec 65K+
07 E320 Bluetec 43k+
05 Nissan Frontier NISMO 4X4 72K+


07 Kawasaki Vulcan 900 5k+ gone
87 300SDL 158k+ gone
91 300D 113k+ gone
83 300SD 220K+ gone
89 300E sold
87 190E sold
83 380SEL sold
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Thanks!!!!

Hey CJ,
Let us know how it goes for you. May be a good sideline business too...

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'99 S420 - Mommies
'72 280SE 4.5 - looking to breathe life into it
'84 300SD Grey - Sold
'85 300SD Silver - Sold
'78 Ski Nautique

I may just have mine rebuilt for me. I have a client at a local Bosch diesel injector facilty in Baltimore that will take care of me.