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How to rebuild injector correctly????
by
big specht
on 20 Dec, 2005 15:51
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I have a extra set of injectors and a pop off tester to check pattern and popoff pressures. Just looking for some info on doing it and what are the best tips to get there are cheap and $$$ ones what works the best
??
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#1
by
vwmike
on 20 Dec, 2005 16:19
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As of now there are mainly 3 different nozzles people are using. Those being the OE replacement ones, 1.9TD, and GTD. GTD is the higher flowing of the bunch. Several people on the board sell them (I normally sell them but am out for another week or so). The biggest problem you will run into is that you will need a selection of shims to adjust the pop pressure which aren't typically available although many can be ordered from VW. The problem is that you need to know what sizes you need before you order them. I can get shim kits with a selection of all of the sizes but they aren't incredibly cheap. I'm just thankful that I can get them. Otherwise, making the injector halves seal back together can sometimes be difficult and you wouldn't really know it was going to leak until it was on the car if you're using a hand operated pop tester.
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#2
by
Justin
on 20 Dec, 2005 17:31
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a good way to see if the injectors will seal up is get a flat surface with some lapping paper and run the flat spot of the upper half of the injector on it until it shines, if the whole thing shines then it should seal up just fine, if its a little iffy then i would try another top injector half
later
Justin
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#3
by
Master ACiD
on 20 Dec, 2005 18:58
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i dont have an injector tester but in my expierence used injectors awalys have something wrong with them. i at one time thought i could be frugal by buying a slew of used injectors for pennies each and having them tested, any using only the good ones.
after testing probably 50 used injectors, i managed to find 4 that had halfway decent breaking pressure and spray pattern.
a place fairly close to me rebuilds injectors, turbo or non turbo, for $35 each. its a bosch certified rebuild centre and i have known the owner for atleast a decade. they put new nozzles in, set the breaking pressure and double check everything to make sure its all good. they can actually take non turbo injectors and bump them up to turbo spec without charging any extra.
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#4
by
vwmike
on 20 Dec, 2005 20:24
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Most of the time you'll find pop pressure is much lower than spec after 10+ years of service. I've seen many TD injectors pop around 1800-1900 psi when they should be at 2250 or so. I even had one injector which was sent in as a core where the spring was broken in 3 peices and I had to remove the nozzle from the holder with a hammer and drift. You just never know what you're getting with used injectors.
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#5
by
kuggkrans
on 20 Dec, 2005 22:42
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What is the final torque setting?
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#6
by
Justin
on 21 Dec, 2005 05:52
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55 lb-ft is the final torque, or 75 nM
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#7
by
vwmike
on 21 Dec, 2005 11:21
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I'll second the overtorqueing. The spec is like 51-52 but it takes more than that to make it seal.
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#8
by
big specht
on 23 Dec, 2005 17:20
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Thanks for all the info guys
My car is a 86 golf na and is dd which nozzles would work the best and not hurt my mileage that bad, you know how it is power or mileage :x
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#9
by
57ringo
on 11 Jan, 2006 06:35
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So can one of you guys fix my injectors from my 98 TDI? I had them checked and the shop said 3 popped at 400-500 below normal ( they said about 3100 was normal) and 1 popped at 1100. That cylinder had a melted piston top.
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#10
by
X@V
on 11 Jan, 2006 10:52
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Did someome try the GM 6.2D injector nozzles?
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#11
by
vwmike
on 11 Jan, 2006 12:34
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With pop pressure that low I would be concerned that one of the springs may be damaged or something. Raising pop pressure 2000 psi would take an entire extra shim.
I haven't tried the 6.2 injectors myself though.
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#12
by
kuggkrans
on 12 Jan, 2006 05:49
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I have seen a home made pop tester in some thread here in the forum, but i cant find it can anybody help me find it.
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#13
by
TDForNow
on 18 Feb, 2006 10:43
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Affecting the breaking pressures will affect your injection timing. As the injector wears and the breaking pressure lowers, the timing advances. The spray pattern also declines with age, somewhat offsetting the advancing of the timing (the poorer spray takes longer to burn).
With redone injectors often the max fuel can be increased for more power without additional smoke.
Andrew
That partially answered a question I have had. How much is the timing affected for each 100bar change in popping pressure? Also, how high can you raise it (breaking pressure) and what imposes the limit (eg; fuel lines, IP, head, etc) I know the higher the better (better atomization and cleaner/faster burn in my mind).
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#14
by
TDForNow
on 18 Feb, 2006 10:46
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Enjoy. Chicks dig trucker cologne.
Andrew
LOL, mine doesn't. Maybe I've been wearing it too long :oops: