6.5 Diesel Injector Rebuild

[dbrannon79]

Here is what it looks like after one 30 minute cycle in the ultrasonic cleaner. take note of the nozzle and tip. the tip is shorter and has no flat spot on the tip. Not sure if the marking on the nozzle is heat discoloration or carbon, but it also seems to have some etching on the side where the part numbers are. I will run it through another cycle and see if it cleans up any better, also get the part numbers on both the body and the nozzle after the second cleaning finishes. I also measured the shim washer too, it seems to be the same as the non-marine injectors.

 

[dbrannon79]

Here is after the second cleaning cycle. it came out much cleaner and I was able to read the part numbers. the discoloration is still on the nozzle so it what looks like etching in the metal on the side of the nozzle too.

it's a India Bosch injector part number 0430 211 054 419

The nozzle showing India Bosch stamped 884 and circled 902 and shows part number DN 0 SD 311

Here are some pics for close observation.

 

[dbrannon79]

@Will L. @Big T @ak diesel driver @MrMarty51 I figured I would tag y'all to see this one, forgot to do that when I posted the teardown.

 

[Will L.]

More of 4,000 psi from the ip.
As to the 100.000 mile intervals- that isn’t from GM, that is from me at the fleet and many others who figure it out.
I think it is more the spring weakening,
Because we have cleaned injectors and they still spray ok- but at a lower pressure.

That one injector you have that was super gummed up- it’s something that got on it after removing because it’s equally covered inside & outside the engine.

 

[ak diesel driver]

IIRC Ferm said the IP is capable of 8-10,000 psi.

 

[Big T]

@Will L. @Big T @ak diesel driver @MrMarty51 I figured I would tag y'all to see this one, forgot to do that when I posted the teardown.

Your fingernails are too clean. Need to get back to some serious wrench work.

 

[Will L.]

IIRC Ferm said the IP is capable of 8-10,000 psi.

Could be. I know it goes over 3500 because I had injectors running at that.

 

[MrMarty51]

I will say this, I am happy that I sent that tester over to You.
You have taken this thread far beyond anything that I would have done. Especially like adding that extra pressure gauge.
That sonic cleaner seems to be a mighty fine tool too. I should get one of those for cleaning brass cases. But then, seems I have not had time to do some shooting so reloading has not been an option too.

 

[dbrannon79]

I think it is more the spring weakening,
Because we have cleaned injectors and they still spray ok- but at a lower pressure.

This is what I am thinking as well seeing that all the ones I've messed with seem to work find other than the low pressure.

That one injector you have that was super gummed up- it’s something that got on it after removing because it’s equally covered inside & outside the engine.

Agreed, I had at first thought it was old diesel but I have no idea where or how long these sat out of an engine. The inside of the upper body was caked full of it too. can diesel gum up like this?

 

[dbrannon79]

I will say this, I am happy that I sent that tester over to You.
You have taken this thread far beyond anything that I would have done. Especially like adding that extra pressure gauge.
That sonic cleaner seems to be a mighty fine tool too. I should get one of those for cleaning brass cases. But then, seems I have not had time to do some shooting so reloading has not been an option too.

those cleaner can be used for a multitude of things. I wish I had gotten a bigger one. I've watched several DIY videos on how to make one. maybe later on I might attempt that. making one would be much cheaper than buying a large one. watched one where a guy took one of those large stainless serving tubs like you find in a commercial kitchen and made his own, then he made one from a commercial stainless sink!