Thread: TD5 INJECTOR TESTING INFO.

Originally Posted by gofer

hi folks. tossing up whether to rebuild original cooked motor (by previous owner ). '99 disco 2 TD5.
most folks i talked to said 90% chance the injectors would be screwed.
so, looked into getting them tested or replace with "was running ok when removed " injectors on 2nd hand market.
only a few firms in aussie set up to test these injectors.
heard tales of having to sell your 1st born and morgage your house to pay for testing in aussie. :-(((

in vic, AG diesel in clayton. contact area on website was not working !!
and Cornell Fuel, in Sunshine.
cornell got back to me , quoting $154 inc GST / injector. apparently the injectors have to be dismantled, cleaned, and rebuilt before they can be tested. Afraid to ask about rebuild.

further checking on this site came up with "Feather-Diesel.co.uk " posted a few years ago.
firms still in business. worldwide postage etc. going strong. has good feedback from landrover sites in u.k.
service centre replied:- £30 + Vat ( 20 % ) for testing.
regards service repair :- basic re-seal £38 + Vat.
Full rebuild / callibration £150 + vat
no idea what postage would be, but they do free collect etc in u.k. and state they have good overseas rates etc.

in this crazy world we live in, it can take 2 weeks to get a small package from melbourne to ballarat where i am, yet only 3 working days uk to aussie for approx same cost.

above stuff is for general info, and no ,i have no ties with any of the firms above.

gofer

Unbelievable, 3 weeks for a small package from melb to ballarat! we send stuff and it's overnight from Melb. Your mailer must be using the slowest mail service in imagination or the cheap skate postage.

Originally Posted by Roverlord off road spares

Unbelievable, 3 weeks for a small package from melb to ballarat! we send stuff and it's overnight from Melb. Your mailer must be using the slowest mail service in imagination or the cheap skate postage.

its 2 weeks mario.
unfortunately you've spoiled those of us on this site.
company concerned starts with a " t " and to be fair its there local delivery system from there depots. not the main firm. although as far as i'm concerned its there responsibility.

ever thought of setting up an injector test rig in your back shed :-)))))

I was thinking about this and it should be relatively easy to make up providing you have a few things.

1/ Old head (or the facilities to make a jig like the head)
An old head would be the easiest way as it includes the pressure regulator, galleries and wot not.
If you have the machine shop you could fabricate the same tube to be bolted to, with a fuel line in.
The old head would need the other 4 injectors closed off top and bottom, or you could just put dummy injectors.

2/ hand pump or old fuel pump
If old head then an old fuel pump to get the 4bar as it would be going through the normal paths.
The jig would definitely be good for a hand cranked pump as getting the 100ml of fuel to 4bar would be easy I reckon, simple piston arrangement.

3/ Gauges
A gauge for the fuel system, so you can confirm it's at the 4 bar, especially if hand pump.

4/ Hand lever to pressure the injector
I'm not sure how much pressure the injector *actually* needs on the top to get to the injection pressure. Consider that you tend to screw the tappet (which isn't a tappet really) down by hand to full stroke and back off, so a decent lever would get you the same force as the cam shaft does (I know, not really a cam shaft).

5/ Manual or auto injection pulse
If the injector works like I think then you could:
* put pump on, wait for 4 bar (or pull piston handle down)
* pull injector handle down (injector pressurised)
* fire injection pulse (micro controlled, you send go it gives an x millisecond or microsecond pulse)
* observe spray pattern.
* profit!

If the pressure leaks, like cranking an engine over by hand, then the injector stroke may need a bit more speed and a microswitch to fire the injector at the end of the stroke automatically.

Testing of injectors AFAIK comes down to a few things:
* injector release pressure - not relevant to the TD5 ones
* spray pattern - visible MK1 estimation in all cases?
* quantity - collection of injected fuel and measurement (the only tricky one as you are talking small quantities, like <5cc?)

Anyone got an old head and an injector laying around? I do have the injector replacement to test compression which could be used to measure the size for a simple machined out item.

[QUOTE=steve_a;2828433]I was thinking about this and it should be relatively easy to make up providing you have a few things.


Did anything come of this?
Just replaced the seals and washers but its still hydraulic locked up in the mornings with fuel.
Next step is to try genuine seals and washers like I shoulda in the first place, but it would be good to get the injectors tested while they're out

Nope, in fact there was that moment of scrolling down and going, wait, that's me! I posted that.

Still sounds like a good idea :0

Just on this fact of buying injectors, are the injectors interchangeable?
If so would they have to done as a set?
Would one set have an advantage over the other in the case of the D2 versus D2a?

I know there is the pressure is different and therefore the black may not be able to take the extra pressure but would that also mean the green need higher pressure to operate effectively...

Just musings

Arty

Why don't you just remove the injectors and turn the engine by hand or on the starter and see which cylinder spits diesel out. Or just get a syringe with a bit of hose on it and suck each cylinder.

That should be enough to see which injector is crook.

if you want to be pedantic, if you can start it at idle, then connect a Nanocom and see what the % deviations are per cylinder. The TD5 injection compares the acceleration of each cylinder from each firing and adjusts the next firing from the crank sensor.
Small % s like 2% are OK but if more than say 5% it means something is wrong

EG leaking injector washer

.
Regards Philip A