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Date:         Fri, 14 Sep 2001 19:33:09 -0700
Reply-To:     Shawn Wright <swright@SLS.BC.CA>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Shawn Wright <swright@SLS.BC.CA>
Subject:      Rebuilding diesel injectors?
Content-type: text/plain; charset=US-ASCII


Does anyone have experience with replacing/rebuilding diesel injectors? After doing some reading
about how nozzles become pitted with age, I decided to pull an injector on my 1.6TD to take a
look, since it has at least 250k km on it.


It appears the nozzle face is definitely pitted, with a slight depression approx. 3-4mm in diameter
around the injector needle. The needle itself appears is not tapered on the end, and I'm not sure if
it was to begin with or not.


I can assume the nozzle or whole injector needs replacement, but I seem to have two options: a
rebuilt injector for ~$70CDN which I assume is complete, or a nozzle for either $20 or $48 CDN,
depending on which model, I suspect the TD uses the more expensive one. Does the nozzle also
include a new needle? If so, I would go this route, except how do I know if the injector opening
pressure is correct with the new nozzle?
The book says there are shims to adjust the pressure (mine is stamped with 155bar), but of
course I don't have to tool to test this.
Has anyone gone through this already who could offer some tips?


ThxShawn Wright, I.T. Manager
Shawnigan Lake School
swright@SLS.bc.ca
http://Zuiko.sls.bc.ca/swright
http://www.sls.bc.ca
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