Diesel Injector Testing

Page updated 02-01-15

Turn-a-round times for testing & repairs is about 24hrs

email  p@remmington.plus.com

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Common rail injectors.  We are equipped to test & repair most types of piezo injectors.  Most types of piezo injectors are repairable.  Repairs are possible on 65% of injectors, average repair cost is about £45 per injector.  Some of these injectors can cost up to £400 each & may need programming to engine position.  So testing rather than substitution makes financial sense.  Please mark each injector, before removal with its engine position i.e. Number 1, Number 2, Number 3, Number 4, 5 or 6.  As we need to know the engine position to phase & test this type of injector.  Injector position needs to be known for re-fitting.  The standard industry method for marking injectors, is applying a light centre punch dot marks to the injector body, 1x dot = pos 1, 2x dots = pos 2, 3x dots = pos 3, 4x dots = pos 4.  Or for very fragile injectors, tiny blobs of nail varnish.

We are now able to test & repair the Bosch CDi version 3 common rail injectors.  These 1600 bar injectors have a seven hole spray pattern & a more powerful electromagnet resulting in more rapid firing of the injector and lower current consumption.

Labour charge for testing is £15 for each injector.

Mail order customers, return postage & packing is £6.00 each per injector or £12.00 a set.

PD-UIS combined injector pump units.   We are equipped to test and repair the standard Bosch P type unit injector.  We are able to test many other types of unit injectors but spare parts availability is hit & miss for any manufacturer other than Bosch (it's new technology).  Please mark each injector-pump unit, before removal with its engine position i.e. Number 1, Number 2, Number 3, Number 4, 5 or 6.  As we need to know the engine position to phase & test this type of injector.  Injector position needs to be known for re-fitting.  The standard industry method for marking injectors.  Is applying light centre punch dot marks to the injector body, 1x dot = pos 1, 2x dots = pos 2, 3x dots = pos 3, 4x dots = pos 4.  Or for very fragile injectors, tiny blobs of nail varnish.  Please phone us about specific vehicle applications...

Labour charge for testing is £27.50 for each unit.

Labour charge for repair to each injector £POA (price on application).

Mail order customers, return postage & packing is £7.00 per unit or £13.00 a set.

  Card payments can be made over the phone by ringing 01553 782929.  Monday to Saturday 8.30am - 5.30pm.

An alternative method for marking injectors, involves cleaning the injector bodies with Acetone or Methythlated Spirits, allowing to dry, then painting dots on the bodies with quick drying brightly coloured nail varnish.

We do not sell, sets of exchange injectors.  With some later, common rail, UIS-PD systems.  Exchange is not a practical option due to the pre-programmed 29 bit identifiers (Can 2.0B)

As a matter of information, we do not recommend ultrasonic cleaning for any injector with an electrical connection.  Some companies do enact ultrasonic cleaning.  We do not...!  We believe it affects the long term reliability of the electrical components.

Also we have never needed to use an injector seat cutter for refitting common rail injectors.  Only exception, when may need one is for a Mercedes Vito, if the injector seats have been leaking.  But normally the cylinder head is past restoration and will need an expensive replacement. 

Common rail injector tester.

 

Common Rail High Pressure Pumps.  We have a test bench plate adapter to mount Bosch single port pumps.  We can drive and phase & test for pressure and volume.  Our workshop stocks most common spares, any unusual spare parts will need to be ordered over night from Leicestershire. 

Testing fee is £59.50 (to include return packaging & postage/insurance).

 

Conventional diesel injector testing.  Nozzle tests & adjustment for injection nozzle opening pressure, leakage, spray-pattern & chatter characteristics tests.  Assessment of correct injection spray, regarding shape and atomisation (injection spray image).

Prices for testing & repair of injectors.

Labour charge for testing, set of four injectors £20

Labour charge for testing, set of six injectors £26

Labour charge for adjustment £10 to each injector.

Labour charge for repair £10 to each injector.

For mail order customers, return postage & packing is £8.00 for a set of injectors.

We do not exchange injectors by the set, we test-adjust-repair as required (it works out cheaper for the customer).  Our workshop stocks most common spares, any unusual spare parts will need to be ordered over night from Leicestershire.  We do not regrind internal injector needles, we just source & fit new ones.

If you have a corrupted injector body, don't be put off by the fact we don't sell exchange injectors.  We have hundreds of used bodies lying about, we will be happy to give them away (free of charge).  This way, we can make you up a matched & fully functioning set, cheaper than exchanging them.

It is a fact in the auto repair trade, most sets of suspect diesel injectors are not tested.  They are just exchanged, at a very high cost to the customer.  Which means allot of people are buying allot of injectors they do not need!

Most sets of dysfunctional injectors can be adjusted up.  Out of a set of four or six, it is normally only one injector, that causes running problems.

We can test conventional injectors with standard M12 or M14 connections & two-spring nozzles, stepped nozzles & UI-UP applications.  Including nozzle sizes R, S and T. 

Our new Bosch EPS 100 is accurate to +/- 2.4 bar.  This means that even the most minute leaks can be analysed and prevented so that the possibility of engine shake at idle can be ruled out.

Bosch EPS 100 for testing standard injectors.

Mercedes CDI engines.  Later type diesel injector suffer leakages.  Lack of a thick copper sealing washer results in blow by of combustion gases, this leads to carbon build up (known as 'black death' in the trade) around the injectors which can seize the injectors solid in the head.  One of the first signs of injector leakage is fumes inside the vehicle.  Both issues more common on the Sprinter and Vito than other applications.  Injectors can be removed sometimes by soaking them in thinners, over the course of a few days.  Most-all of the carbon must be removed to get rocker cover off.  It is rumoured, main Merc dealers, will not quote for injector removal on Vito van diesel engines, because 50% of the time they end up replacing the cylinder head.  In E-class Mercs, the dealers just wreck the injectors with a slide hammer and bill the customer for a new £400 ish per injector.  We have a special £1200 puller made in Spain at our workshop to remove these injectors, its a very cost effective answer to this nasty problem.

 

secondhand EDC diesel pumps - rail injectors - HP pumps & parts for sale