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6.5 Diesel Injector Rebuild

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.

IMG_5841.jpgIMG_5842.jpgIMG_5843.jpgIMG_5844.jpgIMG_5846.jpgIMG_5850.jpgIMG_5851.jpg
 
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.

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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.
 
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.
 
Will L. said:
I think it is more the spring weakening,
Because we have cleaned injectors and they still spray ok- but at a lower pressure.
Click to expand...

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.

Will L. said:
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.
Click to expand...

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?
 
MrMarty51 said:
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.
Click to expand...
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!
 
Well I’m back at it. Working to rebuild a full set of injectors to go in the 93 truck.

The two I had already gone through I had to open up and clean up. The diesel had started to varnish up! Interesting I’ve never seen diesel varnish up that quickly before

Got those two knocked out fairly quickly, ran them through the ultrasonic cleaner. Had to add one shim to one of them and now both are popping off right at 1950.

Doing this to see if the knock sound on the 93 disappears with a set of fresh injectors. Later on I’ll be testing and inspecting the ones coming off it.
 
Before swapping in all the injectors… and seeing as this is the occasional knock sound…
Disconnect any muffler/ cat/ soot traps/ such and such devises. Open pipe is best here for this repair

Do the water down the intake system that many understand like wmi. Blast out all the built up carbon. Carbon on piston top can really effect a lot.
 
Will L. said:
Before swapping in all the injectors… and seeing as this is the occasional knock sound…
Disconnect any muffler/ cat/ soot traps/ such and such devises. Open pipe is best here for this repair

Do the water down the intake system that many understand like wmi. Blast out all the built up carbon. Carbon on piston top can really effect a lot.
Click to expand...
Should I attempt this even with three pistons with “dimples” ??

Remember this engine has chewed on gp tips in a previous life!!
 
So I can still do that but after doing injectors? I figured I’d get the injectors since I still have the intake off and it looks like I might be able get at the ones behind the turbo if I pull the IP lines back off without pulling the turbo!
 
Rebuilt the 4th injector. Dissembled it and found the fire ring was stuck. Finally got it out and I can see it was completely roasted! This is on another set I’m rebuilding for the 93. Opened up another on that’s varnished up to use for parts. Stole the fire ring for this one

image.jpg
 
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