So an update of sorts, no particularly great solutions, but here is what I found:
Standard o rings which are close are 4x1.0mm and 3x1.5mm (inside diam x diam of rubber, note that some vendors use OD x diam of rubber so be careful). While standard sizes it seems most of the o ring kits and even automotive and HW stores don't carry either of those sizes. Plenty of places on line that do carry them so I ordered both. Turns out the 4x1.0mm is very close and works for a short time but started leaking after a few (10 or so) miles. The 3x1.5mm is just a bit too big; it would not go into the injector and I did not want to use excessive force (because I did not want the tip to break off, and wanted to be able to remove these as well).
At this point I was stuck, as whatever else I got was going to take a week to arrive, so I got creative. I put one of the 3x1.5mm rings on a tip, then carefully used a razor to trim a tiny amount of the width off. Smoothed it a bit with some very fine emery, cleaned and greased it. Well it now fit, and so far has not leaked. Sort of an emergency fix, and not really recommended, but hey. So while I continued "testing" this solution, did some more research and bought some other possibilities.
As folks pointed out, some places do sell just the o rings. Place in oregon. Likely any Bosch injector rebuild place would have them too. The owner at AccurateDiesel.com sold me some and they got here quickly (BTW he thought I was after Chevy Duramax diesel stuff as that is what is specializes in, but they use the same injectors as our CRDs).
I also spoke with some o ring manufactures. One was willing to do a special run if I knew what size I needed, but that seems excessive (unless one of our vendors was interested in it). But they suggested using one of their standard 1.5mm diam rings only at a smaller ID, so that it would stretch some and effectively thin down the rubber.
To that end, I ordered some 2.5x1.5mm rings too, just to experiment. Finally got everything in, brought out the micrometer, and here's what I measured. Note that measuring soft things like rubber is difficult as it distorts as the micrometer jaws reach it, all of these measurements are at best approximate (I would not trust them to place a custom order or the like).
Original orings from AccurateDiesel measure as 3.8x1.25mm. When put on a tip the OD of the rubber is 6.0+mm
3x1.5mm orings measured 6.3 and 6.1mm OD on a tip (two different brands). It was the 6.3mm one that would not fit in the injector. The 6.1mm one might fit and work without shaving, have not tried it.
2.5x1.5mm orings measured 6.0+mm OD on a tip. Although they were a bit hard to get onto the tips, seems likely they would work.
Anyway, likely a big fuss over nothing. But if you are ever stuck and need an return oring solution, and can't wait for one of the proper ones, best to try and source a 2.5x1.5mm ring and stretch it over the tips. Failing that a 3x1.5mm can be made to work for you, depending on the brand it may fit, or you may need to do some trimming.
HTH someone.
_________________ 2006 KJ CRD
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