Engine/Transmission (1998.5 - 2002) Nozzle pop pressure & torque

[aphyfe]

I just got Jammer 3's and have not had them tested yet before install. I have cleaned and intstalled them in the bodies (one at a time of course to avoid mixing the parts up)



What is the specified nozzle test pressure in psi and what variation is allowed or can be reasonably achieved?



From the diesel injection shop owners: are the pop pressures usually all over when just replacing the nozzles, or reasonably close.



Also what is the torque for reassembling the injectors.



Any info would be greatly appreciated. I have not worked on this stuff for many years, but have good experience with Cat 3406 a&b model fuel injection pumps and systems.

 

[aphyfe]

Bump

Can't believe with all the "Knowledge" on here I can't get an answer!

 

[aphyfe]

bump

I would really like an answer! Anybody?

 

[Jim Fulmer]

Couldn't tell you on the pop pressures except to check and see if there all close to the same, on the T/Q I just got them tight!



Jim

 

[Cooker]

On a 12v injector the pop pressure is on the injector body. I haven't looked at enough 24v injector to pay attention if it is or not.

 

[JCulp]

well itjust depends some nozzles pop off at 10,000psi some of the newer inj-popoff at 20,000 i dont know your exzact set up and i dont know about those inj. but the range at where they pop off should be pretty close if the pres range i all over i would be alitle concernd beacause your spray pattern will vary with-psi also attomization of the fuel i dont know if that is what you are asking for sorry hope it gives you an idia thanks josh

 

[RonA]

24 valve injectors are set around 300 bars. They tend to drop down about 10 to 15 bars after a few miles. They should all be close to each other. I was told within 5 bars was good. DDP does better than that.

 

[Marco]

305 Bar

That's the correct pop off pressure. Not about or close to...

305!



Marco

 

[BIG CAM III]

i just finished the tip swap out with the jammer 3 tips ,and i dont think you have to check the pop off pressures.

from what i read on another thread was to hand tighten and then tighten

30 degrees.

after the intall the truck sounds smoother and my tach is rock steady.

 

[aphyfe]

pressure

305 bar, Thankyou, I read that 33 ft/lbs for VW TDI injectors is reccommend, the unit is close to the same, so that will probably work.





Some responses from any one who has tested these after installation and can tell me wht the average variation is before shimming to get them exact would be great!

 

[KERMA]

Not 33 ft-lb for the VW injectors, I think people sometimes misread that. It is hand-tight plus 30 degrees.



You should get them pop tested after you install them, it will be interesting to see the results.

 

[aphyfe]

Had the injectors (jammer 3's) tested and re shimmed. 2 of them were very high (+30 bar) and the other 4 were about 20 bar low, They reshimmed and got them all within 1 bar. Runs very nice and power is great :-laf with the BD box turned off. Took some of the harsh rattle out of it too. The idle is very smooth and hits evenly on all cylinders but the computer hunts slightly for the proper idle speed and when you let the clutch out (without feeding pedal) the engine surges more than it used to until the clutch is locked up. Is this normal with bigger than stock injectors?



I would reccommend everyone replacing tips to have them set and checked, I cleaned the parts and installed the new tips so all they had to do is test and reshim them and they only charged me $80. Not sure if I am allowed to post the shop that did them but they are a quality injection shop that has been around for many years here in central PA.

 

[Oil Burner]

by all means, tell us who set them up. My jammer 4 tips are sitting on the table waiting to be installed. I have my old injector bodies in the toolbox in plastic ziplock bags.



how long did the shop take to shim them?



Thanks,

Jason

 

[NUTNDUN]

I am going to take a wild guess that the shop is Deisel Injection there off of exit 77 on 81. I can't remember the exact name of the place but I think that name is close LOL. Yes please post the shop, I want to order the stage 5 tips and get em setup on the stock injectors while I have the 275's still in.

 

[aphyfe]

Laing Diesel in Williamsport PA. 570-494-0874. I guess there is no harm in posting a good repot on a business or product, i don't think it is against the rules.

 

[KERMA]

Had the injectors (jammer 3's) tested and re shimmed. 2 of them were very high (+30 bar) and the other 4 were about 20 bar low, They reshimmed and got them all within 1 bar. Runs very nice and power is great :-laf with the BD box turned off. Took some of the harsh rattle out of it too. The idle is very smooth and hits evenly on all cylinders but the computer hunts slightly for the proper idle speed and when you let the clutch out (without feeding pedal) the engine surges more than it used to until the clutch is locked up. Is this normal with bigger than stock injectors?



I would reccommend everyone replacing tips to have them set and checked, I cleaned the parts and installed the new tips so all they had to do is test and reshim them and they only charged me $80. Not sure if I am allowed to post the shop that did them but they are a quality injection shop that has been around for many years here in central PA.

You should get the pop pressures re-checked in a couple thousand miles. They will probably change.



You should not have to shim the injectors if the nozzles are well matched (ie above average or exceptional quality)

 

[turbo torque]

I put jammer 3's in last week, didn't pop test them and it runs smooth and strong.



Maybe I got lucky. It sure can't hurt to get them tested. I just didn't have a shop near by on a Saturday w/pop tester.

 

[jwilliams3]

34 ft lbs is what it took to get some tips loose the other day with a bar type torque wrench.