Changing A Diesel Injector Nozzle

CHANGING A NOZZLE IN A BOSCH OR LUCAS/CAV INJECTOR

MOUNT THE INJECTOR UPSIDE DOWN IN THE VICE.
Picture 1 shows this.
This will prevent spring and shim from falling out when you unscrew the bottom
nozzle retaining nut (the threaded section with a 27mm hexagon nut)

PICTURE 1

USING A 27MM LONG REACH SOCKET AND PLENTY OF LEVERAGE
UNSCREW THE BOTTOM NOZZLE RETAINING NUT IN AN ANTI-CLOCKWISE
DIRECTION.
Picture 2 shows this
You don't need the socket with a window...we used it to make the picture clearer.

PICTURE 2

PICTURE 3

PICTURE 3 SHOWS THE NOZZLE EXPOSED AFTER YOU LIFT AWAY THE NOZZLE
RETAINING NUT. CAREFULLY LIFT AWAY THE OLD NOZZLE (WITH THE PIN INSIDE)

FITTING THE NEW NOZZLE.
CLEAN ANY CARBON AND DIRT OUT OF THE NOZZLE RETAINING NUT.

FAMILIARIZE YOURSELF WITH THE NEW NOZZLE...YOU WILL SEE IT HAS A PIN
WHICH FITS IN IT'S CENTRE. TAKE CARE THIS STAYS IN PLACE.

REMEMBER YOU ARE GOING TO FIT THE NEW NOZZLE UPSIDE DOWN SO MAKE
SURE THE PIN DOES NOT FALL OUT AS YOU LOCATE IT IN PLACE.

WITH THE NEW NOZZLE IN PLACE CAREFULLY REFIT THE NOZZLE RETAINING NUT
AND SCREW IT DOWN BY HAND AS FAR AS YOU CAN.

FINALLY... TIGHTEN USING
LEVERAGE....AS A GUIDE IT NEEDS TO BE AS TIGHT AS IT WAS WHEN YOU UNDID IT.

WE HOPE THIS GUIDE IS HELPFUL BUT WE CANNOT BE RESPONSIBLE FOR THE
REFITTING OF ANY NOZZLES. PLEASE ONLY ATTEMPT THE JOB IF YOU FEEL
COMPETENT TO CARRY IT OUT.

© Andy Hewing 2010