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Old 08-08-2011, 02:05 AM   #1
Type2Teach
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Default Injector Leak-off Test

Do you think you have a bad injector? Here's a VERY simple test you can do to determine if you have one or more injectors that are already dead or on their way out.
In fact, it's SO simple that while you are doing regular maintenance, it might be a good idea to check the injectors before one leaves you stranded. And from what I've read on the list, it's WAY easier to get injectors out of a hot engine than a stone cold one.
1. Purchase 3/8" ID clear tube from home depot- 2ft
2. Cut it in 4" lengths.
3. Take injector cover off
4. Pull clips off of each of the return fittings on top of the injectors
5. DON'T LOOSE THEM (I keep a clean peanut butter jar with lid around just for this purpose- they store the cut sections of tubing in them when not holding the clips)
6. Carefully pull the return line plastic fittings up and off the injectors (they can break- I've never broken one, but I have read on the forum that the only source for them is Andy)
7. Unplug the Cam sensor (next to injector #5)
8. Fit one tube over each injector head
9. Using a vice grip and cardboard, pinch the fuel return line BEHIND the "T" for #5 injector- fuel can come backwards out the fittings and you can have a mess on your hands.
10. Crank the engine for a full 10 seconds- it won't start because you have your cam sensor unplugged.
11. Check for one or more tubes that are overly full. Andy told me that 2.5ml or more fuel in the tube meant that it was time to replace the injector. I just measured this and in that 3/8" tube on the injector, that would be right at 1 and 1/2" or 37mm for the rest of the world.
Here's a picture of an obviously bad injector followed by two pictures of the same engine (mine) with the #2 injector replaced and other injecters following suit after about 500 miles.
Attached Images
File Type: jpg injector test 1.jpg (60.9 KB, 1709 views)
File Type: jpg injector test 2.jpg (54.8 KB, 1598 views)
File Type: jpg injector test 3.jpg (54.7 KB, 1575 views)
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Old 08-08-2011, 03:26 AM   #2
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Default Re: Injector Leak-off Test

Thanks Joel! I had been searching for a concise write up of the DIY approach for this since you replied to my hot start problem post the other day.
I'd found the service manual version at this post:
http://sprinter-source.com/forum/sho...&postcount=124
Your way is more my style... I'll give it a go this week.
-Alex
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Old 08-08-2011, 04:00 AM   #3
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Default Re: Injector Leak-off Test

No problem, Alex. I was surprised that there was no DIY write up on it, and I actually just heard about it from another member when I tried it. I never saw that post you linked to.
It was just so simple and effective and I had photos, so I figured I would take a few minutes to write it up. Good luck and let us know the results of your test.
PS- if you happen to have a bad injector and need to replace it, there's a great write up on it here in the T1N Write-Ups section. I did #2 and my experience was an easy one. I didn't need the special puller. I'm replacing #5 tomorrow, and I'm hoping I won't need the puller for that one, either.
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Old 08-10-2011, 06:12 AM   #4
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Default Re: Injector Leak-off Test

Thanks for the write up and the pics. Also, you can get a hose clamp at Harbor Freight for about $4-5.
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Old 01-13-2012, 08:30 PM   #5
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Default Re: Injector Leak-off Test

thanks for this. andy told me how to do this on the phone the other day and i was a tiny bit confused. this make it all come into focus. should check it this weekend.
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Old 04-11-2012, 12:16 AM   #6
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Default Re: Injector Leak-off Test

Thank you for sharing a great write up. One question, where did you get the new injectors from and how much should I expect to pay per injector?
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Old 04-11-2012, 01:14 AM   #7
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Default Re: Injector Leak-off Test

WAYNERODD in Ohio had them cheaper than anywhere else I could find... MUCH cheaper.
That's his username. Just do an "advanced search" and you can find his contact info.
I'm sure Andy (Dr. A) in Pittsburgh has some and so does Europarts SD.
All are good sources for parts with plenty of recommendations.
Europarts lists the Stealership price and then their price, just to give you a reference.
Europarts also rents the injector puller, which I rented but didn't end up needing.
I'm glad my post helped.
Good luck and keep the list posted!
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Old 04-11-2012, 01:37 AM   #8
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Default Re: Injector Leak-off Test

When you replace the injectors, do you have to get new seals and hold down bolts? I seen Dr. A make mention about getting new bolts in one of the many posts I have read. My fear is not having everything needed to complete the job, since this is my only work truck.
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Old 04-11-2012, 03:18 AM   #9
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Default Re: Injector Leak-off Test

Quote:
Originally Posted by SewerRatz View Post
When you replace the injectors, do you have to get new seals and hold down bolts? I seen Dr. A make mention about getting new bolts in one of the many posts I have read. My fear is not having everything needed to complete the job, since this is my only work truck.
I first ordered two from Europarts and they came with new bolts and washers. Then I found WAYNERODDs posts and ordered 3 more from him for a much better price. His too came with new bolts, washers and anti-seize.
So it seems to me that it's standard to come with all the necessary replacement parts, but it wouldn't hurt to ask when ordering.
PS- all told, It probably took me less than 2 hours total, start to finish, from the time I disconnected the negative battery cable to start the injector replacement to the time I re-connected it and started the van back up again with new injectors. The first one was real slow, because I didn't know what I was doing, but they all came out nice and easy.
I think it helped that the engine was warm and I had left PB Blaster soaking in the injector wells for a week while I drove the van around during it's normal driving routine.
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Old 06-01-2012, 10:15 PM   #10
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Default Re: Injector Leak-off Test

I am new to this forum and work on five sprinters 3 04-05's and 2 2011's and i just completely rebuilt the 04 did not cut any corners everything new and today i installed the injectors and was ready for the first start-up. Got all the air out and engine fired up just like that once it got fuel and everything was working great and had it running to do a/c on it and then took it for a bit of a test and got back and went to do one last check for leaks and noises before putting the van back into service then i started to give a knock at idle the rpm's would increase and knock then drop and the knock would go away and would surge like that while it idled and i would increase the rpms and the knock would go away then back at idle it would surge and knock again so i read the forum about the leak test and all injectors go up about 1/2" up the tube with fuel and was wondering what that meant. These are new not reman Bosch Injectors and any help would be much appreciated
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