200 TDI Injector Rebuilding - Defender Source
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  #1  
Old February 14th, 2016, 08:06 AM
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Robert Davis
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200 TDI Injector Rebuilding

So the ultrasonic cleaner is on order and my friends doing clandestine work have just picked up 24 new Bosch 200TDI injector nozzles.
I already have the pop-tester and will give a try at rebuilding some injectors.
Will keep you posted when the nozzles arrive.
Have sent some members free used 200TDI Injectors so I only have 2 out of my spare set left, but will start with them and let you know how things progress.
Don't have a cost yet, but am thinking the time and parts will put the cost at about $100 - $120 each.
The goal is to offer a reman set at 20 - 35% cheaper that anywhere else.
The only issue is scheduling the time for a quick turn around when people have a vehicle down for the injector refirb.
Will look for a couple of used ones so there is a set of 4 to swap out minimizing down time.
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  #2  
Old February 14th, 2016, 08:34 AM
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Excellent idea. I just went through this and wish I'd pulled mine early on in the swap process. Additional downtime of two weeks could have been avoided. In hindsight it is a no brainer as tips don't last a lifetime and bad injectors can damage IP's.
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  #3  
Old February 14th, 2016, 09:03 AM
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Robert Davis
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Bad injectors can do all kinds of things to an engine, but the effects are usually not permanent, just hard to start and poor running, smoking, and so on.
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RDavisinVA

Uncle "Richard" Douglas has a Land Rover with big wheels that never gets stuck... until he breaks something so it won't go. Uncle Douglas always breaks something. - Anna Crowther at the Conclave 2012 (AKA Carburetor Neck)

"What's with this death wobble, Uncle Douglas, I can't keep it in 1 lane?"
UD: "Just Power through it man!"
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  #4  
Old February 14th, 2016, 11:43 AM
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Don Bunnell
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Robert - are you going to offer anything for OM617 injectors? I just ordered a set of #315 from Greazer on Peachparts but just wondering for down the road.
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  #5  
Old February 14th, 2016, 12:43 PM
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I have been doing the Mercedes OM617 Injectors for years.
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RDavisinVA

Uncle "Richard" Douglas has a Land Rover with big wheels that never gets stuck... until he breaks something so it won't go. Uncle Douglas always breaks something. - Anna Crowther at the Conclave 2012 (AKA Carburetor Neck)

"What's with this death wobble, Uncle Douglas, I can't keep it in 1 lane?"
UD: "Just Power through it man!"
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  #6  
Old February 15th, 2016, 02:10 PM
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Don Bunnell
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Quote:
Originally Posted by rdavisinva View Post
I have been doing the Mercedes OM617 Injectors for years.
Ah jeez - had no clue - should have asked you first!
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  #7  
Old February 17th, 2016, 10:03 AM
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Great service idea. I rebuilt mine with new bosch tips and it was a fiddly job that requires some finesse
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  #8  
Old February 17th, 2016, 10:11 AM
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I have an extra set if anyone needs to borrow them in a pinch.
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  #9  
Old February 26th, 2016, 04:03 PM
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Nozzels are here.
Now just need to crank up the sonic cleaner and make up the line to pop test the rebuilt units.
So many tasks, so little time!
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RDavisinVA

Uncle "Richard" Douglas has a Land Rover with big wheels that never gets stuck... until he breaks something so it won't go. Uncle Douglas always breaks something. - Anna Crowther at the Conclave 2012 (AKA Carburetor Neck)

"What's with this death wobble, Uncle Douglas, I can't keep it in 1 lane?"
UD: "Just Power through it man!"
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  #10  
Old February 26th, 2016, 04:08 PM
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You doing two stage setting or just the main pressure?
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  #11  
Old February 26th, 2016, 05:11 PM
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Got a price point for rebuilding a full set?
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  #12  
Old February 26th, 2016, 06:42 PM
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Quote:
Originally Posted by Red90 View Post
You doing two stage setting or just the main pressure?
Have only done a couple with a single first stage pop-off at 200 BAR using a borrowed fitting for my pop tester.
If you know a short cut or can provide more insight, am all ears as I am planning a trip out to see someone who does this setting all the time and work an afternoon as an unpaid intern to learn exactly how it's done.
To date all the Mercedes Injectors are single stage injectors that pop only once at 1950 PSI.
I have rebuilt lots of Mercedes injectors successfully for my own use.

------ Follow up post added February 26th, 2016 06:45 PM ------

Quote:
Originally Posted by 1of40 View Post
Got a price point for rebuilding a full set?
Too early in the game, but won't be the $600 to over $1,000 asked for them rebuilt and NOS by others.
Not planning to cash in, just "help a brother out"!
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RDavisinVA

Uncle "Richard" Douglas has a Land Rover with big wheels that never gets stuck... until he breaks something so it won't go. Uncle Douglas always breaks something. - Anna Crowther at the Conclave 2012 (AKA Carburetor Neck)

"What's with this death wobble, Uncle Douglas, I can't keep it in 1 lane?"
UD: "Just Power through it man!"
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  #13  
Old February 26th, 2016, 07:43 PM
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My understanding was you need a computerized flow/pressure test machine to measure and set the 2 stages fully. Most people don't do it.
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  #14  
Old February 26th, 2016, 07:54 PM
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subscribed and following this - great stuff
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