W204 2007 C320 CDİ Cleaned fuel injectors - problems

[Artist]

Hi folks and thank you in advance for any help or advice offered.

So this morning i set about removing and cleaning the injectors. TBH the removal and cleaning went well and i did just one side the engine (3 injectors - pushed for time) and whilst i was at it changed the fuel and air filter. İ tested each injector by spraying carb cleaner through the nozzles before i replaced them and got a nice spray pattern on each one.

All back together and i fire up the engine but it wont immediately start...after a minute or so it starts but wont rev and starts knocking. İ get plumes of smoke so i switch it off. İ try once more but its the same and i decide the engine knocking is too bad to keep running or trying further.

Not sure what I've done wrong but i found a video from redat.com that says you have to preload the amplifer module inside the injector with iso oil and a compression tool....i didn't do this as i was unaware. İs my problem or are there others factors at work here.

Car is now at my lockup undrivable as i ran out of time strip it down again.

Any thoughts or suggestions?

 

[mersum1es]

You might have got a air lock in one or more injectors. These %/%¤¤%( piezos should do one at the time, start the engine and get air out by revving...

I read there would be special 'injector bleeding actuation' is SDS but I have not checked it personally. Are you sure there are only one bottom seal per injector (you managed/remembered to get them out) ?

 

[star]

Why did you “clean” them? Never cleaned a injector. However it sounds like you have knackered one and it’s injecting too much or leaking badly.

 

[john campbell]

Why did you “clean” them? Never cleaned a injector. However it sounds like you have knackered one and it’s injecting too much or leaking badly

I would also agree that you have damaged a injector.......... Remove them again and take them to a specialist to recon them otherwise replace with new.

 

[mersum1es]

Nozzle removal/change is basic thing, but true, cleaning them rarely needed.

 

[Doug1234]

How did you clean the injectors ?, did you dismantle them ?.
Did they go back in the same cylinder they came out of ?.
If it was mine I would go and restart it and give it at least a couple of minutes running and see if it settles down

 

[alexanderfoti]

This is the kind of machine that is used for testing and calibrating common rail injectors:



By replacing the nozzles like that, its impossible to set any of the required parameters correctly.

fit 6 re-manufactured injectors, recode the injectors and live and learn.

 

[Artist]

Why did you “clean” them? Never cleaned a injector. However it sounds like you have knackered one and it’s injecting too much or leaking badly.

İ think i missed the bit where you preload the amplifier module with oil so basically with that not working its just flooding the barrel with fuel. I'll be stripping them down again and sorting that before buying some refurbed ones and recoding.

İ took care and numbered the injectors so they all went back to their respectivd cylinder.

The main reason i decided to clean them is the car keeps going into limp mode and occasionally stalling at low speed. The fault codes indicate high pressure due to possible fuel blockage. İ.e fuel injectors and fuel filter.

 

[Artist]

You might have got a air lock in one or more injectors. These %/%¤¤%( piezos should do one at the time, start the engine and get air out by revving...

I read there would be special 'injector bleeding actuation' is SDS but I have not checked it personally. Are you sure there are only one bottom seal per injector (you managed/remembered to get them out) ?

İ did mate...they each had new copper washers and went back into the correct cylinder. İ think I've found the issue which is i didn't preload the amplifier module with oil and check it was working correctly before reassembling and refitting

 

[Artist]

Why did you “clean” them? Never cleaned a injector. However it sounds like you have knackered one and it’s injecting too much or leaking badly.

İll be restripping and preloading the amplifier module later today to see if that sorts it. I'll do a video and post it up for future reference

 

[Artist]

This is the kind of machine that is used for testing and calibrating common rail injectors:

View attachment 68753

By replacing the nozzles like that, its impossible to set any of the required parameters correctly.

fit 6 re-manufactured injectors, recode the injectors and live and learn.

Fortunately i only did one side the pots so three were done. İ think i know what the issue is and I'll work out a way to preload the amplifer modules with oil and make sure its working before refitting to the cylinder's

 

[Artist]

Thank you for your input so far...as I've said in the replies I'm going to remove them all later today, disassemble them and preload those amplifier's.

Either way if i fix or don't fix I'll post up a video for future reference.

 

[mersum1es]

The main reason i decided to clean them is the car keeps going into limp mode and occasionally stalling at low speed. The fault codes indicate high pressure due to possible fuel blockage. İ.e fuel injectors and fuel filter.

It can also been due to leak in system. High pressure is teiggered when system suddenly gets enough delivery. With that fault code, I would check injector tank leaks first, then make tests for fuel quantity valve and pressure regulator.

 

[mattkh]

Thank you for your input so far...as I've said in the replies I'm going to remove them all later today, disassemble them and preload those amplifier's.

Either way if i fix or don't fix I'll post up a video for future reference.

If the injectors are Piezo ones, then are you aware that they are very sensitive to shock, you cannot even drop them onto the worktop..

 

[Artist]

If the injectors are Piezo ones, then are you aware that they are very sensitive to shock, you cannot even drop them onto the worktop..

No... I didn't know this but I've been very careful so far

 

[Artist]

It can also been due to leak in system. High pressure is teiggered when system suddenly gets enough delivery. With that fault code, I would check injector tank leaks first, then make tests for fuel quantity valve and pressure regulator.

Yes I'm getting powertrain faults. The car runs perfect until i give it a bit of welly and then pretty soon will go limp mode. İ put it back together today and I'm not seeing much diesel coming through....those amplifers are very suspect items

 

[mioba]

Could also be an air leak. Running to lean then going into limp
mode.
The beauty that is self diagnosis. Time and money!

 

[mattkh]

İ put it back together today and I'm not seeing much diesel coming through....those amplifers are very suspect items

What ate these amplifiers..?

 

[Artist]

What ate these amplifiers..?

See this video

 

[Artist]

Preloading the amplifier failed to sort the issue. İ checked fuel supply to the lead off connectors and all is good so my only conclusion is the injectors need testing and a refurb. Off they went to the diesel doctor this afternoon.

Let me know if you want the vids of me removing the injectors and disassembly/reassembling