Injectors and pump advice please

[kitchenman]

Hi all,
For the last few years I have had warning from the MOT tester that emissions are getting too high, I spoke to a injection specialist today who run the engine and blipped the throttle hard a few times, there was black smoke
He said everything was OK but the problem is most likely the injectors, it has done 134K.
He offered to service them, I said I would get them out and to him, he was OK saying it would save me money and spent some time pointing out possible problems I may have in getting them out.
I have always worked on petrol engines so know very little about diesel engines, but am confident I can get them out, I am sure my tool kit will include all I need

Advise as to pitfalls to look out for please

He said he would service the injectors for around £35 each
If this was not the total answer he could service the pump guestimating around 4-6 hours [£40 per hour] remove service and refit plus parts, at <£300.
Seemed reasonable to me around £800 max to sort the problem.
The car is good no other problems so to me a reasonable investment for many more years use.
It has never had an advisory for rust or anything else BUT the tester did point out a small problem that will need fixing, some rust in the chassis behind the NS rear wheel below the seat belt bolt.

 

[solarman216]

First a question, Bosch or Zexell, Rick

 

[jims-terrano]

When were the fuel and air filters last changed? Do you buy fuel from a supermarket? I stopped using supermarket fuel a few tank fulls before mot and I noticed a big difference in the way the truck runs and also apparently it’s emissions were down. Once passed I’ve gone back to supermarket simply for convenience.

 

[kitchenman]

How do I identify the pump?

Filters are all changed either yearly or at designated mileage, all within last few K miles

Yes Tesco fuel

 

[terranosaurusdoug]

Try sending some Liquimoly Diesel purge through the system before spending loads on injectors, you can get it off of ebay and it's easy to do, there are youtube vids of how to do it :thumb2

.....oh and stop using crap supermarket fuel, your truck will thank you

 

[solarman216]

How do I identify the pump?

Yes Tesco fuel

Two easy ways, top left of engine, big round cable connector amongst others, and Bosch Maff = Bosch pump, oblong connector and Hitachi Maff = Zexell, however you can test your own injectors, but too complicated to write so if you want to try this I can talk you through it, it is not rocket science, Rick

 

[kitchenman]

Thanks Rick, I have a manual pump I think, there is no electricery
There is no intercooler, direct from turbo to manifold

 

[kitchenman]

Try sending some Liquimoly Diesel purge through the system before spending loads on injectors, you can get it off of ebay and it's easy to do, there are youtube vids of how to do it :thumb2

.....oh and stop using crap supermarket fuel, your truck will thank you

Liquimoly Diesel purge ordered on ebay due mid week, thanks for the tip.
I will try other fuel for a while, what is best?

 

[terranosaurusdoug]

Liquimoly Diesel purge ordered on ebay due mid week, thanks for the tip.
I will try other fuel for a while, what is best?

I'm liking esso at the moment, MrK on here says shell is good and he is an F1 winner so I tried and was as good, esso is closer for me though I actually notice a difference in how my truck drives, if someone borrowed it and filled it up at morrisons I would be able to tell!!

 

[jims-terrano]

Tdoug, your truck goes well full stop mate.

 

[solarman216]

Thanks Rick, I have a manual pump I think, there is no electricery
There is no intercooler, direct from turbo to manifold

Do you have rubber leak off pipes tween the injectors or metal? Rick

 

[kitchenman]

Hi Rick,
Metal, the guy at the injector shop made a big thing of warning me not to damage them when undoing the thin nut holding them down, said to put a tube over the injector and hit it to shock the nut

 

[terranosaurusdoug]

If metal then you have the hitatchi/zexel setup.....is what Rick is going to say :lol

 

[solarman216]

T D is correct, if memory serves me correctly you need a 27 mm socket to get them out, no need for the special socket for number 1 as you do not have the sensor wire, will check in the morning, Rick

 

[kitchenman]

T D is correct, if memory serves me correctly you need a 27 mm socket to get them out, no need for the special socket for number 1 as you do not have the sensor wire, will check in the morning, Rick

Thanks Rick, I will wait to see how the treatment stuff goes, but will get the penetrating oil out anyway

 

[jims-terrano]

Just thinking, other than being mentioned each MOT is it causing any other problems for you?
Is it worth trying the moly stuff to see if it makes any difference. Then depending on your mileage could you use the moly stuff again a couple of tank fulls before test and then filling using a good brand of diesel for the two or three tank fulls before test. Also take it for some good runs to get it nice and hot to burn crap out of it before the test.

 

[terranosaurusdoug]

I'm just making sure Kman, you know not to poor it in the tank yeh?

 

[kitchenman]

video shows how, I will most likely put it in the filter when I change it.

 

[terranosaurusdoug]

Its easy to do, this is what I did....
https://youtu.be/6xlnuh2KgKI

 

[solarman216]

Sorry Dave 27 mm is for the Bosch, Zexel is 22 mm a deep socket is required, you can test them yourself if you aquire a spare injector pipe but care is needed as the pressure is high enough for the spray to penetrate skin, Rick