Injectors - ever had yours checked / tested?

petem

petem

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TimeOut asked a question on another thread regarding Injectors and how often they should be checked and the consequences of not checking them.

I believe that for some engines (e.g. D2's), VP specify that injectors are checked at the same frequency as checking Valve Clearances, i.e. every 2 years or 500 hours. For others, such as my KAD44's, there is no mention of injectors in the Maintenance Schedule.

Injectors that are not functioning correctly can impact performance and economy and 'hosing' can potentially damage pistons. Some people state that injector issues will manifest themselves, for example smoky engines, and therefore pre-emptive checking is unnecessary.

I've just had the valve clearance on my boat checked / adjusted and was advised to have the injectors removed and tested (their removal is a simple task if done when valve clearances are being checked). The cost if testing them is relatively trivial (<£100 or so per engine).

If any issues are found I believe they can often be adjusted. If they are too far gone (as mine were being the originals) then they will require new nozzles. New injectors from Volvo are around £400 or £150 for a recon unit. Speciality firms can also refurbish injectors using OEM nozzles for under £100.

I shall be interested to see the effect that correctly adjusted valves and new nozzles will have on the engine. They already run pretty sweetly (usually) but I'm missing a few ponies so not quite achieving factory full speed. Hopefully, I'll get some of my horses back and we'll be back to 37kts WOT:).

Having had a new set of injectors, I think I'll get them checked every other valve clearance check (so every 4 years).

What do others do? If I've misunderstood anything, feel free to correct me!
 
I think my injectors were checked as part of a full engine survey just before I bought the boat and were found to be as new, as were both engines. Then at around 1600hrs.
I've now had the boat 10 years and haven't checked them since, as both engines run cleanly and I service it religiously every year. Now on 2600hrs.

But they are non-turbos, so not as highly stressed, that may be significant.
 
I think it depends on the type of fuel injection. With respect to electronic unit injectors, as I have on my D-12's, here's Latestarter's comments from a couple of years back

Latestarter1 said:
Sorry guys NO NO NO, leave the unit injectors well alone .... Never change EUI unless the diagnostic tool tells you to and then ONLY change that injector never the whole lot.
Click to expand...
 
petem said:
TimeOut asked a question on another thread regarding Injectors and how often they should be checked and the consequences of not checking them.

I believe that for some engines (e.g. D2's), VP specify that injectors are checked at the same frequency as checking Valve Clearances, i.e. every 2 years or 500 hours. For others, such as my KAD44's, there is no mention of injectors in the Maintenance Schedule.

Injectors that are not functioning correctly can impact performance and economy and 'hosing' can potentially damage pistons. Some people state that injector issues will manifest themselves, for example smoky engines, and therefore pre-emptive checking is unnecessary.

I've just had the valve clearance on my boat checked / adjusted and was advised to have the injectors removed and tested (their removal is a simple task if done when valve clearances are being checked). The cost if testing them is relatively trivial (<£100 or so per engine).

If any issues are found I believe they can often be adjusted. If they are too far gone (as mine were being the originals) then they will require new nozzles. New injectors from Volvo are around £400 or £150 for a recon unit. Speciality firms can also refurbish injectors using OEM nozzles for under £100.

I shall be interested to see the effect that correctly adjusted valves and new nozzles will have on the engine. They already run pretty sweetly (usually) but I'm missing a few ponies so not quite achieving factory full speed. Hopefully, I'll get some of my horses back and we'll be back to 37kts WOT:).

Having had a new set of injectors, I think I'll get them checked every other valve clearance check (so every 4 years).

What do others do? If I've misunderstood anything, feel free to correct me!
Click to expand...

Mine are off being done right now. Had them done when I got the boat and I've done 1000 hours more so off they go again.
 
Hi Pete,

Went through the same process with my Targa 40. According to the engineer the tips were in need of replacement. That said I never notices any difference. New turbo's gave me another 100 RPM. The dropped a prop size and had the same speed approx but at correct WOT. In the end it was just too much junk and toys on board. Difficult decision.

Rob
 
petem said:
TimeOut asked a question on another thread regarding Injectors and how often they should be checked and the consequences of not checking them.

I believe that for some engines (e.g. D2's), VP specify that injectors are checked at the same frequency as checking Valve Clearances, i.e. every 2 years or 500 hours. For others, such as my KAD44's, there is no mention of injectors in the Maintenance Schedule.

Injectors that are not functioning correctly can impact performance and economy and 'hosing' can potentially damage pistons. Some people state that injector issues will manifest themselves, for example smoky engines, and therefore pre-emptive checking is unnecessary.

I've just had the valve clearance on my boat checked / adjusted and was advised to have the injectors removed and tested (their removal is a simple task if done when valve clearances are being checked). The cost if testing them is relatively trivial (<£100 or so per engine).

If any issues are found I believe they can often be adjusted. If they are too far gone (as mine were being the originals) then they will require new nozzles. New injectors from Volvo are around £400 or £150 for a recon unit. Speciality firms can also refurbish injectors using OEM nozzles for under £100.

I shall be interested to see the effect that correctly adjusted valves and new nozzles will have on the engine. They already run pretty sweetly (usually) but I'm missing a few ponies so not quite achieving factory full speed. Hopefully, I'll get some of my horses back and we'll be back to 37kts WOT:).

Having had a new set of injectors, I think I'll get them checked every other valve clearance check (so every 4 years).

What do others do? If I've misunderstood anything, feel free to correct me!
Click to expand...

So at you saying you have had new injectors or refurbished units?
The 44/300 is a 2 stage injector , in past years I've changed many due to poor performance especially on the heavier boats , of course this model is always cursed with the worn turbo syndrome but having the injectors tested then set up correctly will give good results .

You have not said who has done the work which of course makes a difference especially if they are not conversant on how to set the valves up.

For the record the place I use for testing does NOT charge for testing so whoever is saying it's a£100 is on the make or he's not going to the right pump shop around Southampton.

Of course the time to remove them is chargeable on any engine.
 
volvopaul said:
So at you saying you have had new injectors or refurbished units?
The 44/300 is a 2 stage injector , in past years I've changed many due to poor performance especially on the heavier boats , of course this model is always cursed with the worn turbo syndrome but having the injectors tested then set up correctly will give good results .

You have not said who has done the work which of course makes a difference especially if they are not conversant on how to set the valves up.

For the record the place I use for testing does NOT charge for testing so whoever is saying it's a£100 is on the make or he's not going to the right pump shop around Southampton.

Of course the time to remove them is chargeable on any engine.
Click to expand...

Paul, I believe my injectors are being refurbished with new Bosch nozels (IIRC). The price for the work includes the testing but I'll double check what the testing alone would have cost.

Do you ever recommend that injectors are checked or just wait for issues?
 
rlw said:
Hi Pete,

Went through the same process with my Targa 40. According to the engineer the tips were in need of replacement. That said I never notices any difference. New turbo's gave me another 100 RPM. The dropped a prop size and had the same speed approx but at correct WOT. In the end it was just too much junk and toys on board. Difficult decision.

Rob
Click to expand...

Yep, I suspect Turbos will be the next thing! Does anyone know if the Turbos can be reconditioned or any other solutions to avoid Volvo Penta costs?
 
Yup turbos are OEM. I think KKK but volvopaul will know. less then half the price of the green version for mine :) A spraycan later and you cannot tell the difference.
They looked at a rebuild but when the housing was cleaned of rust there was not enough metal left.
 
PB Asher (Southampton opposite Ikea) offered to test all 12 of my jerk injectors for ~ £40 inc vat as a single batch. If any fail then these will be extra - they are all going in over Winter.
 
petem said:
Yep, I suspect Turbos will be the next thing! Does anyone know if the Turbos can be reconditioned or any other solutions to avoid Volvo Penta costs?
Click to expand...

Yes. I have had one done on a kad32 as it was allowing oil into the aftercooler.
 
It's a Marine Air VLD16 (16,000 BTU's) - http://citimarinestore.com/en/index.php?controller=attachment&id_attachment=102. It was new/old stock but the supplier assured me it was a very nice unit (all stainless steel). It's been installed and tested but the through hull fittings haven't been made yet as I didn't want the hassle / expense / risk of another lift (and I can live without A/C over the winter).

I don't think I knew you lived in Cheltenham. Whereabouts?

Pete
 
I think they are better run up now and again over the winter ,esp if they heat in order to test the reversing valve ,as if it's never used it may cease .
How about getting the two hole .s cut ,water in below the W/ L and water out just above ( with sea cocks ) at the lift out ,
It's DIY er able -this way the sealant would have set by the time it's reaches the Med .

Injectors -- MAN suggest pull them every 1000 hrs @ the same time as adjusting the tappets .
Test them and replace any defective tips ,Bosch .
I ve got a few spare and the puller tools in the spare parts kit which came with the boat .
It's not something I,am gonna do diy - I will get a tech to do it .
Regarding, what happens between now and the 1000 hr mark ,we have load % guages and various electronic sensors ,EGT ,L / hr etc
So if one or more injector was to play up I would hope it would be picked up .
Scrolling back we have water in fuel alarms and I do add an additive at fill ups "Startron " which reckons to dissolve /mix any water into the diesel along with kill the bug and its residue if any is supposed to be burn,t off safely .
We run 30 micron primary's and2x 2 micron secondary's each has a water drain cock ,the primary's clear bowls

Adopting a more preventative approach, rarther than sit back and write cheques ---

I,am working on the assumption either water of dirt ,especially water knackers the tips .

Due to the high temp / pressure the hydrogen creates a lot of heat which does the damage ,ruins the spray pattern and in extreme cases prevents it closing , or something along those lines ?burns a massive hole leading to hosing and piston damage .

So really it's down to how effective you mitigate water ingress -- on a boat , filler cap seal , dodgy fuel pontoons etc ,water dripping on your tank out of sight and so on .
If you can stay one step ahead of the water ,then the injectors should last
 
Last edited:
petem said:
It's a Marine Air VLD16 (16,000 BTU's) - http://citimarinestore.com/en/index.php?controller=attachment&id_attachment=102. It was new/old stock but the supplier assured me it was a very nice unit (all stainless steel). It's been installed and tested but the through hull fittings haven't been made yet as I didn't want the hassle / expense / risk of another lift (and I can live without A/C over the winter).

I don't think I knew you lived in Cheltenham. Whereabouts?

Pete
Click to expand...
Get it done when lifted onto truck. Add fittings and stub them off
 
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