Think No.6 Injector was f****d?

[ian2000t]

Took my injectors out to ge them refurbed, and this is what was left in the head when I took No.6 out. It was thick soot, almost like coal! Took ages to get that bloody washer out as there was a hard lip of soot all the way round!:
http://i103.photobucket.com/albums/m144/ian2000t/Volvo/IMAG1390.jpg

The other 5 looked fine... like this:
http://i103.photobucket.com/albums/m144/ian2000t/Volvo/IMAG1391.jpg


Ever since I've had the car there has always been a loud "clacking" noise around 1500rpm and the idle is a little lumpy.. rocks the car a bit. With the rebuilt injectors that seems to have gone now, so I think I can assume No.6 injector was well past it's best!!


I've had the injectors rebuilt by a local diesel shop, putting in the Monark nozzles I supplied and setting pressure to 165 bar.... My god the difference!! It's quieter now, smoother, and I gave it a heavy booting in 2nd gear and it pulled straight to 5,000rpm - with the old injectors it would give up and go really sluggish above 3,300rpm!

They've also thoroughly cleaned the injectors so they look like new - all for £50!

http://i103.photobucket.com/albums/m144/ian2000t/Volvo/IMAG1392.jpg
http://i103.photobucket.com/albums/m144/ian2000t/Volvo/IMAG1394.jpg

[IceV_760]

Problem wasnt really on nozzle itself, nor injector. Problem was leaking sealing. Somehow it has leaked there.
Maybe it was with too loose torque on head, or there were tiny bit of trash under sealing surface.

But very cheap price for repair. And nice to hear your car works proper way now :)

[ian2000t]

Good point, hadn't thought about it that way, but there shouldn't be any combustion up that far I suppose!
So which part of the injector actually seals against what? Does it seal against the washer and the washer seal against the head?

When I took that one out it was extremely tight in the head, all the way until it was nearly out. And I mean really tight - the others were tight, but I had to use a breaker bat on this until it was a thread away from coming out. I really thought it had been cross threaded or something!

After a clean up it went back in fine, so possibly crap in the thread stopped previous owner screwing it all the way down to seat on the washer properly?

Either way new nozzles worthwhile - its never pulled past 3k like that before! Diesel screw is only half turn up from standard setting at moment aswell. Time for more fuel and +5psi now my engine feels healthy!

[IceV_760]

It forms that kind of sooth when it leaks, which is hard as hell. Thats main reason y have to maintain extreme cleaniness when working with
fueling systems. Have seen few of those. No air should get past nozzle to bore where you screw down injector.
Really necessary also to read and fulfill torque-instructions.
I should too either change nozzles or buy totally new injectors ( core and all with 1-year warranty) with a price of 90$ each-
but in my opinion they ARE cheap.

[ian2000t]

That still sounds expensive for injectors.

Mine cost (with "upgrade" Monark nozzles):

- 6 Monark nozzles - £72
- fit new nozzles, clean and set pressures - £50
- 6 new washers - £5
- new fuel hose to loop across injectors <£5

[IceV_760]

Its how you count it :) New is always new. And they probably lasts next 20 years aswell without doing anything for them-
but lets see what i do during autumn and winter.