Injector nozzle replacement

connolcj · **Posted:** Fri Aug 31, 2018 9:43 am

So I'm in the process of replacing/rebuilding my 2006 CRD engine after a valve drop a few years ago. I bought a used engine from someone on here and and mostly using it as my replacement. I'm reusing some of the parts off my old engine as some of those parts we brand new before the engine failure. I plan on reusing three of the four original injectors as there were no problems with them but the last one had the nozzle damaged during the valve failure. I sourced two other injectors when I bought the new engine with the intention of using one of them during the rebuild. I know I will need to have the injector code rewritten if I use one of the and GDE has already been contacted for help in that regard. My question is that I was wondering if anyone had just swapped the injector nozzle/tip from one injector to another? I have watched a few videos on the tearing down and rebuilding of the Bosch injectors and it seems that the nozzle/tip are fairly easy to remove and replace. If I'm able to do this then I won't need to rewrite the injector code saving me some time and money. What are people thoughts? I may try it at first to get it up and running with the intention of replacing it down the line but I wanted to see what other people have done.

gollygeemister · **Posted:** Fri Aug 31, 2018 10:35 am

The nozzle has everything to do with the flow rate of the injector, so swapping it doesn't seem like a workaround. That being said, others have said in the past that the injector trims are mostly to smooth out the engine, and not correcting them won't keep the engine from running.

Mountainman · **Posted:** Fri Aug 31, 2018 11:48 am

You could burn a hole in the piston if the volume is off, so I wouldn't even try to mess with it. Too much to lose. Like the other post says, you can use one of your spares, and I doubt that you'll be able to tell the difference.

vwroad87 · **Posted:** Fri Aug 31, 2018 1:00 pm

I sent my injectors to Oregon Fuel Injection for testing. Mine were shot at 96K miles, OFI said one bad tank of fuel can really damage injectors. I asked OFI to rebuild mine, they rebuild all sorts of injectors as they had done for my 5.9 cummins. OFI laughed and said only Bosch rebuilds these because of highly specialized equipment, they sold me a set of rebuilds from Bosch.

Got the rebuilds and torqued them into place, I didn't do anything with the computer....rig runs perfectly.

Just my experience with these injectors.

WWDiesel · **Posted:** Fri Aug 31, 2018 1:35 pm

vwroad87 wrote:

I sent my injectors to Oregon Fuel Injection for testing. Mine were shot at 96K miles, OFI said one bad tank of fuel can really damage injectors.

The very reason it is most advisable to add a secondary 2 micron fuel filter like some of us have done if you want to protect those very close tolerance parts from contaminated fuel.
The OEM fuel filter is ~10 microns new and quickly degrades from there which could allow contaminated fuel to enter the HP fuel pump and injectors.
A 2 micron secondary fuel filter will help to add additional protection for the expensive CP3 and Injectors.

rancherman · **Posted:** Fri Aug 31, 2018 6:31 pm

OP says that the 'code' needs re-written, and one reply says he replaced all 4, apparently no code issues.

What's this about?
edit; something about how a set of injectors actually flow, and that constant is entered in the computer?

GordnadoCRD · **Posted:** Sat Sep 01, 2018 2:27 am

If you look at the top of each injector you will find an identification code printed there. Each one will be different, most likely. These can be programmed into the ECM as which one goes in which cylinder. The ECM uses these codes to fine-tune each injector so each cylinder is pulling equally. it's pretty normal for a mechanical injection engine to have cylinders that produce differing amounts of power, and the operator doesn't even feel it, but it wastes fuel. These engines will do that too if the ECM doesn't know which code goes to which cylinder. If it's programmed in, it can do fine tuning so it runs more smooth and quiet.

rancherman · **Posted:** Sat Sep 01, 2018 11:22 am

GordnadoCRD wrote:

If you look at the top of each injector you will find an identification code printed there. Each one will be different, most likely. These can be programmed into the ECM as which one goes in which cylinder. The ECM uses these codes to fine-tune each injector so each cylinder is pulling equally. it's pretty normal for a mechanical injection engine to have cylinders that produce differing amounts of power, and the operator doesn't even feel it, but it wastes fuel. These engines will do that too if the ECM doesn't know which code goes to which cylinder. If it's programmed in, it can do fine tuning so it runs more smooth and quiet.

So each individual injector is entered, and the ecm 'knows' that individual's characteristic. Basically the flow.
Put in a different coded injector, and the ecm will still 'drive' it as if it's still the previous injector.. unless it's re coded.
Thanks!

vwroad87 · **Posted:** Sat Sep 01, 2018 12:08 pm

GordnadoCRD wrote:

If you look at the top of each injector you will find an identification code printed there. Each one will be different, most likely. These can be programmed into the ECM as which one goes in which cylinder. The ECM uses these codes to fine-tune each injector so each cylinder is pulling equally. it's pretty normal for a mechanical injection engine to have cylinders that produce differing amounts of power, and the operator doesn't even feel it, but it wastes fuel. These engines will do that too if the ECM doesn't know which code goes to which cylinder. If it's programmed in, it can do fine tuning so it runs more smooth and quiet.

So the encoding has flow data encoded in a simple data type? Is this in the manual? Is it possible for us to us MPPS to "install" the data into the ECM?

Thanks

WWDiesel · **Posted:** Sat Sep 01, 2018 12:19 pm

vwroad87 wrote:

So the encoding has flow data encoded in a simple data type? Is this in the manual? Is it possible for us to us MPPS to "install" the data into the ECM?
Thanks

My understanding is that it requires one of the very sophisticated type programers like the DRBII to enter the codes. :banghead:

GordnadoCRD · **Posted:** Sun Sep 02, 2018 2:09 am

WWDiesel wrote:

vwroad87 wrote:

So the encoding has flow data encoded in a simple data type? Is this in the manual? Is it possible for us to us MPPS to "install" the data into the ECM?
Thanks

My understanding is that it requires one of the very sophisticated type programmers like the DRBIII to enter the codes. :banghead:

Correct.
I believe GDE offers this service as well, but it might require sending the physical unit to them. I'm not sure on that.

connolcj · **Posted:** Tue Sep 04, 2018 8:14 am

Okay thanks for all the replies. I'll go ahead and move forward with GDE reprogramming the codes just to make sure it runs as efficiently as possible. I may see if I can get the one rebuilt and have a spare for backup or sell.

ElvinStrawhat · **Joined:** Fri Aug 24, 2018 7:12 am **Posts:** 1

Once removed from the engine the injectors can be cleaned with a wire brush and washed in a light oil solution. am i right?

brass knuckle

WWDiesel · **Posted:** Tue Sep 04, 2018 10:34 am

ElvinStrawhat wrote:

Once removed from the engine the injectors can be cleaned with a wire brush and washed in a light oil solution. am i right?

Never use a wire brush or sandpaper or any kind of abrasion on the tips, you could damage them!!!! :grim:

Use only on the sides.
Only use a soft cotton rag with some brake cleaner on the tips.

GordnadoCRD · **Posted:** Wed Sep 05, 2018 2:55 am

x2
Any wire or abrasive WILL damage the tips causing poor atomization, incomplete burning, smoky exhaust, reduced power/mileage, and excessive carbon buildup.

My aged formal education in this agrees with the soft cotton cloth, although microfiber didn't exist in those days, and it's likely this would be ok as well.

Clean diesel, or kerosene only to clean. In those days professional shops used ultrasonic cleaners with specific surfactants. IDK what they use now.

connolcj · **Posted:** Wed Sep 05, 2018 7:18 am

Does anyone know a good injector rebuilding that I can send an injector or two to? I'm local to Northern Indiana so a nearby place (1 hour or less) would be a nice option too. Any idea on what it typically costs to get one cleaned or rebuilt?

SargeIndustries · **Posted:** Thu Sep 06, 2018 11:59 am

I sent my injectors to this place in the UK

https://www.specialistdiesel.com/

It was $572 to rebuild all four of them. Shipping could be up to hundred dollars depending how much of a hurry you are in. You will have to send in your originals as cores, they will rebuild your original cores and send them back to you very quickly. Get a calling card and talk to them on the phone. You will be asked what numbers are on top of your injectors, so have in your hand if you decide to call. You won't be able to find what you need by poking around on their website.

Injector nozzle replacement

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