Diagram of a 3rd gen injector?

[steved]

Anyone have a exploded view of a common rail injector... tried searching, but came up empty.



I know I have seen one before, just not sure how I found it...

 

[JVolpe]

I remember seeing one somewhere also, maybe Bosch website, not sure. The DR service manual has about 7 pages dedicated to the injector. Not pictures, but numerous diagrams of the injector and its various pieces. Full detail of removal and replacement with diagrams.

 

[JVolpe]

This is from one of the Bosch websites, it shows a half section. It is not the one I remember but all I see for now.



Bosch Injectors, Diesel Injectors, Diesel Control Module, Diesel Engine Parts

 

[steved]

I'm looking at the 04 manual now, and it just has the basic breakdown, with the injector as a whole.

 

[JVolpe]

Well ok I was reading and not paying attention to the diagrams. I guess your right the only other individual injector diagram is fig 20.



Best I could do with images.



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[steved]

I guess I'm trying to figure out if the solenoid is a replaceable part?



Everything else looks replaceable...

 

[Yo Hoot]

I have loads of cutaway pictures here from the Philadelphia Auto Show a few years back...

This is the 600 (2004. 5-up)

2004. 5 Dodge Cummins Engine Cutaway

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[raychem]

I guess I'm trying to figure out if the solenoid is a replaceable part?



Everything else looks replaceable...

The only parts that are replaceable are the nozzles, soleniods, and the seals.



The body of the injector is a NON-SERVICABLE item which is why when 3rd gen injectors go bad due to a craked body or suffer from excessive return due to a bad ball seat(return side) you have to replace the whole injector.



Hey think about it this way... there only 400. 00 a piece compared to the 6. 7 at 1800. 00 plus each. I am on my second set of injectors on my 3rd gen. Needless to say I only run high pressure boxs on the dyno or to race. I am done with cracked bodies.





Richard

 

[steved]

However, I already have a rebuilt set of injectors in the truck... if I buy a complete set of injectors, I would end up with almost $5k in injectors.



Not that its not doable, but its getting a bit frustrating...

 

[steved]

Any idea where to get just the solenoid?

 

[Joseph Donnelly]

Where do you get $5K? I can get a new set with the upgraded, more durable stainless steel bodies, for around $2300

 

[steved]

I already have $2100 in the injectors in the truck now, and add another $2300 (quoted from you) is $4400 in injectors... in less than a year.

 

[JCobb]

injectors...

Hey Steve,



This is a suggestion, try and buy an oem set (or just one) of used injectors on ebay or something and get a solenoid from them. You can probably find a decent used one for $100 or less. The solenoid is removable and replaceable. I have taken many of these stupid things apart (entirely#@$%!). You think you only have one bad or is it all of them?

 

[JCobb]

injector solenoid...

Forgot to add that I think it is an 1"1/4 wrench which takes the solenoid off. You will have to hold the body of the injector (right near the injector hold down) with either the cummins tool, or do like I did and grind the open end of a 7/8" wrench thin enough to fit on the injector with the hold down on it still. You have to be careful when you do remove the solenoid. Be sure to have the injector upright (in the normal mounted position) when you unscrew it. The reason is because there are several small parts that are underneath it. I will see if I can unscrew one that i have here and take some pics to post for you.

 

[steved]

I think only one is causing issues... at this point, it acts like an injector but who knows.



I did check the resistance, my meter is not as accurate as I would like, but they all ohm'd the same... background was 0. 2 to 0. 3 and all the injectors ohm'd 0. 4. I did NOT take the harness off the injector, but I did unplug the harness at the valve box connection. At least they ohm'd the same...



I need to speak with my father to see if he has a better meter (I know he does). Hopefully he has one that will test solenoids.

 

[JStieger]

Where do you get $5K? I can get a new set with the upgraded, more durable stainless steel bodies, for around $2300

What is the part number for these new stainless steel bodied injectors?



-thanks-

 

[Yo Hoot]

I think it was $1100 for my F1 Stage 1 injectors, not counting labor for the install. This is just nozzles and testing. I have been using Primrose 405 additive in my diesels since 2001 and have yet to have a bad injector. Had mine in since springtime and so far have been very happy. Sht happens though. These injectors aren't like the old days. Steve I hope you get it sorted out. Who nose... . maybe it's something else causing it. Lloyd put mine in. He also did my turbo, trans and head studs. Everything he did is holding up quite well.

I highly recommend Primrose 405 additive as I have had zero fuel issues in 7 years using it.
Tell George I sent ya. He is a diesel fuel expert. If you have any questions about fuel testing and filtration he is the one to ask. .

Petroliance DBA AV Lubricants-Your ExxonMobil Oil Distributor!

 

[steved]

The truck is at Lloyd's...



I have no doubt in Lloyd's repair skills or DonM's rebuild quality... they have both treated me well.



These injectors have 170k on some of their guts, and it not like this happened right after being installed. Parts fail... it just frustrating trying to pinpoint the cause when its not dead parts or blindingly obvious.



Its in Lloyd's care now...