Bosch diesel injector replacement

Automotive
1

It’s been a fun day working on my truck, and I thought I’d share a few pictures.

Some background: I’ve noticed an occasional knocking at idle and under heavy acceleration, which can be caused in a diesel by a leaking injector. A fellow DMS member was kind enough to lend me a scan tool which confirmed a negative fuel balance rate for one injector, and allowed confirmation of the diagnosis by shutting that one off and observing that the knock stopped.

I ordered a new one from Injectors Direct and installed it today. The truck is purring like a kitten again!

The old one, buried back behind the fuel hoses and glow plug controller.

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Several extensions and a crowfoot flare wrench were required.

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Old injector, new injector, the hold down bracket, and the old fuel line.

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Grimy injector bore before cleanup.

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New injector, installed and ready to test!

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Video, or it didn’t happen.

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Thanks for sharing that repair!

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For my next trick: re-routing the PCV line so as not to dribble condensed oil mist down the back of the engine.

(edit: also prevents the intercooler from becoming a coke-plugged mess.)

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I’d forgotten to post these. I used a USB camera to help me clean out the injector bore. Enjoy!

Duct tape and a series of hoses were used to make a custom mini-vac with variable suction.

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Almost clean.

4 Likes
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A few options :
1- reroute the PCV to the ground like in the old days (might stain the driveway tho)

2-install a Mann Hummel Pro Vent

and there are others…

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Neat! I didn’t know #2 existed. I like that option.

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Mann Hummel is the real world’s filter company - the Pro Vent is well made, readily available.

Just trying to help…

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Thanks for the tip. Every little bit helps: injector failure on these trucks is blamed on either the 7-micron fuel filter (too wide) or the ultra-low-sulfur diesel fuel. I’ve solved the latter with an additive (Optilub XPD, chosen because of an independent test) and plan to solve the former with a lift pump → water separator → CAT 2 micron filter adapter. The stock high-pressure injection pump has a gear lift pump to suck the fuel from the tank, which does not have enough cowbell to use the 2 micron filter w/o some help.

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Then there is the option of a tin can option as well. CCV mod on the 7.3 many have done that.

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