zexel injectors

[Tim Gilbert]

Hi all i have been having a few problems with my maverick.

Started out with running poor and eml coming on changed the maf no different changed the cps and i no longer have the eml coming on but then had the engine Kangarooing at above 2000 rpm.

Found the turbo actuator arm was seized up after freeing that of i know have a intermittent misfire at low revs up to around 2500 rpm when it misses there is black smoke.

Have stripped the inlet manifold off cleaned it out and blanked the egr valve off.

So am thinking injectors .... have been reading through the forums and notice the bosh system you can test no1 injector for a ohms reading but not the zexel.

I ran the truck with out the injector plugged in and its not making any difference to the way it runs.

so do i really need it to have the wiring ? no eml light nothing. just my intermittent misfire.

Or would one of the guys who are running the Hitachi system be happy to unplug your injector and see if the get any differences when driving your truck.

Oh i have also found a part number that i believe is the right one for my truck and have found it cross reference to a bosh and Nissan numbers.

zexel part number 105079-003 bosh 9443-610-789 nissan 1661065N00

I am considering getting a set of nozzles instead of complete injectors .

Needs so ideas and pointers please.

 

[Daveluck]

Hi all i have been having a few problems with my maverick.

Started out with running poor and eml coming on changed the maf no different changed the cps and i no longer have the eml coming on but then had the engine Kangarooing at above 2000 rpm.

Found the turbo actuator arm was seized up after freeing that of i know have a intermittent misfire at low revs up to around 2500 rpm when it misses there is black smoke.

Have stripped the inlet manifold off cleaned it out and blanked the egr valve off.

So am thinking injectors .... have been reading through the forums and notice the bosh system you can test no1 injector for a ohms reading but not the zexel.

I ran the truck with out the injector plugged in and its not making any difference to the way it runs.

so do i really need it to have the wiring ? no eml light nothing. just my intermittent misfire.

Or would one of the guys who are running the Hitachi system be happy to unplug your injector and see if the get any differences when driving your truck.

Oh i have also found a part number that i believe is the right one for my truck and have found it cross reference to a bosh and Nissan numbers.

zexel part number 105079-003 bosh 9443-610-789 nissan 1661065N00

I am considering getting a set of nozzles instead of complete injectors .

Needs so ideas and pointers please.

Have you cleaned the injectors?

What I have done on previous diesels is remove the fuel filter, fill it with your choice of injector cleaner, put it back on, start the engine and run for 15-20 seconds. Turn off and leave overnight. In the morning start the van and take it for a quick 20-25 minute Italian tune up.

Clears the tubes so as to speak.

Edit...I'm suggesting the clean because you said there is no difference to the running of the car if you disconnect one of the injectors. It maybe you have a blocked nozzle...Have you checked you have diesel getting to the injector ( crack the HP but and see if you've got diesel?)

 

[Tim Gilbert]

Have you cleaned the injectors?

What I have done on previous diesels is remove the fuel filter, fill it with your choice of injector cleaner, put it back on, start the engine and run for 15-20 seconds. Turn off and leave overnight. In the morning start the van and take it for a quick 20-25 minute Italian tune up.

Clears the tubes so as to speak.

Edit...I'm suggesting the clean because you said there is no difference to the running of the car if you disconnect one of the injectors. It maybe you have a blocked nozzle...Have you checked you have diesel getting to the injector ( crack the HP but and see if you've got diesel?)

Yea Ran injector cleaner through the system as you described along with fuel system cleaner in the tank. new filter ect.

Just dont make scene with that injector i would of expected the eml to come on but nothing.

 

[Banshee]

Hi all i have been having a few problems with my maverick.

Started out with running poor and eml coming on changed the maf no different changed the cps and i no longer have the eml coming on but then had the engine Kangarooing at above 2000 rpm.

Found the turbo actuator arm was seized up after freeing that of i know have a intermittent misfire at low revs up to around 2500 rpm when it misses there is black smoke.

Have stripped the inlet manifold off cleaned it out and blanked the egr valve off.

So am thinking injectors .... have been reading through the forums and notice the bosh system you can test no1 injector for a ohms reading but not the zexel.

I ran the truck with out the injector plugged in and its not making any difference to the way it runs.

so do i really need it to have the wiring ? no eml light nothing. just my intermittent misfire.

Or would one of the guys who are running the Hitachi system be happy to unplug your injector and see if the get any differences when driving your truck.

Oh i have also found a part number that i believe is the right one for my truck and have found it cross reference to a bosh and Nissan numbers.

zexel part number 105079-003 bosh 9443-610-789 nissan 1661065N00

I am considering getting a set of nozzles instead of complete injectors .

Needs so ideas and pointers please.

I've had the kangerooing you have described in my Maverick before on a Zexel setup, once was when I had a split in an intercooler hose and once was when I'd forgot to tighten the jubilee clip up for the same pipe :doh

 

[Tim Gilbert]

I've had the kangerooing you have described in my Maverick before on a Zexel setup before, once was when I had a split in an intercooler hose and once was when I'd forgot to tighten the jubilee clip up for the same pipe :doh

i am sure that was being caused by the turbo lever being stuck as i don't have that happening anymore. i just mentioned it due to my troubles being ongoing.

had all the inlet stripped yesterday and cleaned.

 

[solarman216]

Zexell pumps suffer with this, from what I have read it is to do with spring wear, my Zexell motor does this but just back off the pedal and re apply sorts it, Rick

 

[Tim Gilbert]

Zexell pumps suffer with this, from what I have read it is to do with spring wear, my Zexell motor does this but just back off the pedal and re apply sorts it, Rick

Ummm it makes sense as it's at different rpms.
Spring wear so repairable then lol

Thanks everyone.

 

[solarman216]

Ummm it makes sense as it's at different rpms.
Spring wear so repairable then lol

Thanks everyone.

Yes but take pump off, send it away and minimum cost £100 but likely to be more, that is why I just live with it, Rick

 

[panelbeater]

i think he means no1 injector wire not injector.

 

[Tim Gilbert]

i think he means no1 injector wire not injector.

I have run the truck with the injector wire unplugged and it didn't make and difference to the way it runs.

I get what everyone has said and am at a point of either going for injectors or pump.

I am just a bit surprised that injector being unplug doesn't seem to make a difference so is it needed.

 

[Daveluck]

I have run the truck with the injector wire unplugged and it didn't make and difference to the way it runs.

I get what everyone has said and am at a point of either going for injectors or pump.

I am just a bit surprised that injector being unplug doesn't seem to make a difference so is it needed.

I would have thought if you unplug an injector so that it isn't injecting, it would run at best lumpy and at worse non drivable.

But then i don't really understand injectors that well. Rick and Banshee had to learn me last time!

 

[elty001]

I think you've answered your own question as to your running issue.
If there is no change with the number one injector unplugged my guess would be that it's your problem.

 

[Tim Gilbert]

I think you've answered your own question as to your running issue.
If there is no change with the number one injector unplugged my guess would be that it's your problem.

Yea I would agree with you but I don't understand why I am not getting the eml comming on.

 

[solarman216]

I have run the truck with the injector wire unplugged and it didn't make and difference to the way it runs.

I get what everyone has said and am at a point of either going for injectors or pump.

I am just a bit surprised that injector being unplug doesn't seem to make a difference so is it needed.

Mine is Zexel so will unplug it in the morning and see what happens, will let you know, Rick

 

[Tim Gilbert]

Mine is Zexel so will unplug it in the morning and see what happens, will let you know, Rick

Ok thanks.

 

[solarman216]

OK this is interesting, my off road motor and my daily drive are both Zexel, unplugging both produces no engine management light and no difference to the running, I did 3 miles on my road car and would not know it was unplugged, very different on the wifes Bosch, once unplugged I only managed a couple of hundred yards the light was on and it would not pull the skin off a rice pudding, make what you will of that, Rick

 

[Daveluck]

OK this is interesting, my off road motor and my daily drive are both Zexel, unplugging both produces no engine management light and no difference to the running, I did 3 miles on my road car and would not know it was unplugged, very different on the wifes Bosch, once unplugged I only managed a couple of hundred yards the light was on and it would not pull the skin off a rice pudding, make what you will of that, Rick

Well there you go. I wouldn't of expected that. I would of thought it would have behaved the same as the Bosch.

How strange.

 

[solarman216]

Well there you go. I wouldn't of expected that. I would of thought it would have behaved the same as the Bosch.

How strange.

I have discovered various other differences between the two, for instance to dry out your brakes after going through water on the Zexel you can floor the go fast pedal and hit the brakes, do that on a Bosch and the go fast pedal does not go fast, and the method of retrieving codes with the paper clip is different, if I do the same as the Zexel on the Bosch it clears the codes before reading them, as I can never remember which is which I always use a reader, Rick

 

[Tim Gilbert]

OK this is interesting, my off road motor and my daily drive are both Zexel, unplugging both produces no engine management light and no difference to the running, I did 3 miles on my road car and would not know it was unplugged, very different on the wifes Bosch, once unplugged I only managed a couple of hundred yards the light was on and it would not pull the skin off a rice pudding, make what you will of that, Rick

Thanks for doing that Rick

I am going to gamble and put 4 standard injectors in and see what happens.

Can anyone confirm the correct part number for the zexel.

 

[solarman216]

Update on my test, my daily drive has had the injector sensor disconnected since my last post, but today after my fish meal at the chippy would not start, I tried it three times making sure I had the correct key, and on the 3rd try it fired, when I got home, popped the bonnet to discover the injector plug was still disconnected, so guess that was the reason for the none start issue, I thought I had reconnected it but clearly not, dementia must be setting in, Rick