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Discussion Starter #1
Hi. I need some help AGAIN.

Having got my car back after the ECU and bad wiring were replaced, I have a misfiring injector. My mechanic put injector cleaner in before I left, but it has not helped after about 250 miles. He says we have to arrange to have the injectors taken out and sent for testing, which makes me anxious because I know there's a strong change they will break. At the horrific prices injectors are (I paid £530 for the last round already), I can't afford to replace them.

Is there no way to test which is the problem without taking them out? Is it just that he doesn't have the facility to do that but another garage would?

Additionally, does anyone know the rough price of refurbishing (wrong word, but I can't think of the right one) an injector vs buying one?

Thanks
 

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Fuel injectors again?
As wiring appears to be good, perhaps there is an underlying issue such as bad fuel. I know ever increasing bio content seems to cause problems. Poor quality fuel is an increasing issue IMHO.

If injectors were replaced before, they should come out ok. Normally diesel injectors are only hard to remove when the crush washer fails and soot from combustion gas builds up on the outside.

As for testing injectors in situ, perhaps disconnecting the multi plug of each injector whilst the engine is running and hearing which one makes least difference might be a way. That would introduce fault codes though.

I'd expect costs of perhaps £40-100 per injector for repair/service to remanufacturing with calibration coding on an exchange basis (old injector not broken).

A friend recently took an electronic diesel injector apart recently and cleaned it so as to cure a misfire. He did so with fairly basic tools. Perhaps that is worth trying.
 

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Hi. I need some help AGAIN.

Having got my car back after the ECU and bad wiring were replaced, I have a misfiring injector. My mechanic put injector cleaner in before I left, but it has not helped after about 250 miles. He says we have to arrange to have the injectors taken out and sent for testing, which makes me anxious because I know there's a strong change they will break. At the horrific prices injectors are (I paid £530 for the last round already), I can't afford to replace them.

Is there no way to test which is the problem without taking them out? Is it just that he doesn't have the facility to do that but another garage would?

Additionally, does anyone know the rough price of refurbishing (wrong word, but I can't think of the right one) an injector vs buying one?

Thanks
You can check correction values on mes and do a leak back test on injectors to see if any are way off compared to others.

Assuming you are referring to a Diesel engine?
Has the mechanic checked for other issues like a problem within cylinder,low compression etc?
 

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Discussion Starter #4
Thanks. Yes, 1.9 JTD.

When I got the car back, it wasn't playing up too much. Just extra smoke, and occasional lull in power. He put in 2 bottles of injector cleaner. But about 40 miles later, it started shuddering and there's a nasty cracking/snapping sound with any acceleration (can hear it just idling too, with the bonnet open). So he hasn't yet taken a good look; he just says it is misfiring. I'll make sure he does check everything he can before taking them out. I don't know if they've been taken out before - I've only had it 2 years - but he says they're stuck in there.

Do you happen to know if the type of people he'll be sending the injectors to will likely also be able to recondition/remanufacture?
 

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Until he tries to remove them he won’t know if they are stuck in there,best bet is soak area around injectors with plus gas prior to taking it back to help with ease of removal.

If the place can test injectors I would imagine they can recon them aswell.
 

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Discussion Starter #6
Until he tries to remove them he won’t know if they are stuck in there,best bet is soak area around injectors with plus gas prior to taking it back to help with ease of removal.

If the place can test injectors I would imagine they can recon them aswell.
Thanks. I think he's kind of preparing me for the worst case, since I've spent so much on the car at this point already.
 

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Discussion Starter #8
I could never get Multiecuscan working on my laptop :(

One last question: does anyone have a rough idea how much these places usually charge for injector testing? Starting to feel nauseous at the amount I've spent on it lately, and Google is not being helpful today.
 

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Why not try the old fashioned idea of talking with a specialist? At a guess, just for a test, £50 or so.

If you have not got Multi ECU Scan working it will be a configuration problem.

I'm sure you could start a thread on here and we'll walk you through each and every step with clear and complete instructions. AFAIK, there is not really any decent guides for complete novices here or on MES website...I always found those that knew tended to post comments as though they were giving information to people who knew as much as they did.
I found it a poor situation.

Maybe it is just me. However, your original post was ambiguous enough that I thought you had the injectors done already. Obviously it is not the case- I see that now but it demonstrates the importance of clear communication.
I know I'm as bad as anyone sometimes though- maybe worse in how I interpret things...
 

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Discussion Starter #10
Yes, I can see how the £530 bit could easily be taken as me paying that for injectors - I meant that was what I paid for it being in the mechanics last time (ECU, wiring, MAP sensor).
 

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I've just put my 159 on Multiecuscan and you can see number 3 has a problem but all arent that well as they're meant to be zero
Doesn’t necessarily mean injectors at fault could be mechanical issue low compression etc. Mine were way off due to swirl ingestion.

Also if one is way out of whack another will adjust to compensate to keep smooth idle.
No3 seems to be a common one on these engines due to wiring breaking down,GM do a repair kit as it’s so common.
 

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Doesn’t necessarily mean injectors at fault could be mechanical issue low compression etc. Mine were way off due to swirl ingestion.

Also if one is way out of whack another will adjust to compensate to keep smooth idle.
No3 seems to be a common one on these engines due to wiring breaking down,GM do a repair kit as it’s so common.
No that's right it doesnt , on my 147 i was having trouble with a loss of power ( not massive loss of power but it wasnt a quick as normal) at the time and i was checking everything trying to find the problem and i then checked the injectors which #3 was hovering around 3 so i thought id found the problem and replaced that injector but made no difference to the power or what is was regeristing on multecuscan, the different injector was still at 3 (ish) so i put the old 1 back in.
So then i pulled off the egr to clean it and noticed the 2 thin slots in the manifold where the egr connects were blocked so removed the butterfly valve and the last 3 inches of the manifold is double skinned which again was completely blocked, cleaned that out and the car did go a little better but more importanly number 3 injector dropped back down and was regeristing around 0 , now i dont know if it was coincidence or what but on this 159 i'll be looking at other stuff first before swapping injectors.
 

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Doesn’t necessarily mean injectors at fault could be mechanical issue low compression etc. Mine were way off due to swirl ingestion.

....
Same here, although I hoped it was a dirty injector or dirty lifter that might be cured by a tin of magic, it was 2 bent valves c/o a metal swirl flap mangling them.

It would be premature to conclude it's the injector, though removing them should be no big deal unless the seals are blowing and cementing them in with carbon. If so, the leaky seal will cause uneven compression...

After I fixed my head damage I still had a bit of a rattle, and correction factors seemed widely spaced. I bought a single refurbed injector and substituted that for each injector in turn. One turned out to be problematic and I had that tested and refurbished by Swadlincote diesel, and a second one tested but was OK. The damaged one had been a casualty of microscopic shrapnel from fragments of swirl flap on #3.

But even after all that, it still seemed very rattly at times. At that point I changed all 16 lifters. Better, but it still rattled more than it should:( Until after a few hundred miles it went permanently quiet again, and has been fine ever since.
 

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Discussion Starter #14
As much as I love this car, it's becoming more and more of a nightmare. My mechanic is now having trouble removing the injectors. He said after decades of working on Alfas, he's never yet had a problem removing injectors, and now he can't get mine out.
 

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Coca-Cola; preferably the original high sugar recipe. Let it work in at least overnight. Apparently the acid is good for loosening stick injectors.

Turbo cleaner which is simply commercialised Mr Muscle oven cleaner may work also. Try the easy stuff first.
 

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Discussion Starter #16
Thanks. He says he's tried all kinds of penetrating oil, slide hammer, and has a pressurised puller on it at the moment, but no upward movement. If he is unable to get them out, I'll take it home and just keep trying stuff like this on them.
 
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