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Date: Mon, 23 Feb 2004 10:50:02 -0800
From: Richard Atwell <ratwell_at_mac_dot_com>
To: Type2 <type2_at_type2_dot_com>
Message-ID: <BC5F8B5A.9B49%ratwell_at_mac_dot_com>
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Subject: Injector cleaning

WRT the recent topic, I had my fuel injectors cleaned and tested. I really
didn't know what to expect since they spent 11 years sitting idle and I had
that problem with the sludge in the gas tank but I felt the bus drove well
and had a fair amount of pickup for a 2L engine despite the varnish I saw in
the fuel lines.

I thought I'd share the report. Basically, Bosch originally provided a well
matched set, the o-ring inside one injector failed and it seems no amount of
FI cleaner could restore the spray pattern compared to having them
professionally cleaned.

I haven't driven the bus with them back in yet but if you can't find NOS
injectors at bargain prices cleaning seems like a good deal for $11 each.

Preliminary Test Results
------------------------

Test pressure = 43.5 psi

Test 1. Injector Resistance
2.5
2.5
2.6
2.5

Test 2. Leak Down Test (Pass / Fail)
P
P
P
F <- o-ring failure

Test 3. Spray Pattern (Good / Fair / Poor)
F
F
F
F

Test 4. 90 Second Pulsed Flow Delivery (mL)
76
75
77
75

Test 5. 100mL Pulsed Volume
99
98
100
97

Test 6. 20 Second Static Flow (mL)
74
74
76
74

Test 7. 100mL Static Flow
97
97
100
97

Test 8a. Injector Coil Test - On
5.9
5.89
6.01
5.95

Test 8b. Injector Coil Test - Off
6.2
6.19
6.32
6.24

Test Results After Service
--------------------------

Test pressure = 43.5 psi

Test 1. Leak Down Test (Pass / Fail)
P
P
P
P

Test 2. Spray Pattern (Good / Fair / Poor)
G
G
G
G

Test 3. 90 Second Pulsed Flow Delivery (mL)
79
77.5
78
78

Test 4. 100mL Pulsed Volume
100
98
99
99

Test 5. 20 Second Static Flow (mL)
75.5
75.5
76
75.5

Test 6. 100mL Static Flow
99
99
100
99

Approximate pound-per-hour flow
19.37
19.37
19.5
19.37

-- 
Richard, 1978 Westfalia CDN
http://homepage.mac_dot_com/ratwell
Cupertino, CA