Revised Injection Valve Test (07.3/14)

Publication date: 1990-08-01
Reference number: 07.3/14

REVISED INJECTION VALVE TEST

TECHNICAL SERVICE BULLETIN

Reference Number(s): 07.3/14, Date of Issue: August 1990

REVISED INJECTION VALVE TEST M102, M103, M104, M116/117, M119

Model All Mercedes Benz Models (Gasoline Engines)

Group Fuel System

Bulletin No. 07.3/14

Date August 1990

SERVICE INFORMATION

Attached to this service information is the updated Injection Valve Test for the above-mentioned gasoline engines.

Before replacing any fuel injectors, they must be tested according to the attached procedures. It is extremely important to use the proper test fluid as described in this bulletin.

Failure to use the correct fluid will alter the results of the test (kerosene is no longer approved).

SERVICE INFORMATION - 102.985 ENGINE

102.985 ENGINE - INJECTION VALVES SPECIFICATIONS

INJECTION VALVES	PART NUMBER
MBNA part number	000 078 40 23
Bosch number	0 437 502 010
Opening pressure w/ new valves w/ used injection valves	3.5-4.1 bar (51-59 psi) min. of 3.0 bar (44 psi)

TIGHTENING TORQUE - 102.985 ENGINE

TIGHTENING TORQUE	NM (IN. LBS.)
Injection lines to fuel distributor (reference value)	10-12 Nm (89-107 in. lbs.)
Injection lines to injection valves (reference value)	12 Nm (107 in. lbs.)

SPECIAL TOOLS - 102.985 ENGINE

DESCRIPTION	PART NUMBER
Special Tools	904 589 00 21 00

NOTE: Before testing injection valves, fill container of tester with clean test fluid (e.g. Shell Mineral Spirits 135) and bleed tester.

CAUTION: Never use normal gasoline or other easily flammable/ combustible fluids in valve tester.

Only injection valves which do not meet specifications must be replaced. Always install new seals when reinstalling the injection valves.

TEST PROCEDURE - 102.985 ENGINE

Remove injection valves. Before starting the tests for opening pressure, leak and spray pattern, check injection valve visually for dirt or rust. If rust can be seen in fuel inlet or spray nozzle replace the injection valve. Connect injection valve to tester. Bleed pressure line with shut-off valve open and coupling nut loose. Then tighten coupling nut.

Contamination Test Open shut-off valve. Operate hand lever slowly (2 sec./stroke). If pressure does not build up to 2.0-2.5 bar (29-36 psi), the injection valve has a leak (e.g. wedged particles). Close shut-off valve. Thoroughly flush injection valve by operating hand lever rapidly until valve is completely flushed. The injection valve is completely flushed when there is no further increase in high pitched chattering sound.
NOTE: On new injectors, the first time opening pressure can exceed nominal opening pressure.
Opening Pressure Test Open shut-off valve and read opening pressure while operating hand lever slowly (2 sec./stroke). The opening pressure should be between 3.0-4.1 bar (44-59 psi).
Leak Test With shut-off valve open, operate hand lever slowly. Bring pressure to 0.5 bar (7 psi) below previously measured opening pressure, but not below 2.8 bar (41 psi) and maintain it. No drop should fall from the injection valve tip within 15 seconds (wetness at the tip is normal).
Chatter and Spray Pattern Test Close shut-off valve. Flush injection valve by moving hand lever several times at approx. 0.5 sec./stroke. Reduce hand lever speed to 1 sec./stroke. The injection valve must chatter. The formation of droplets, a cord-like jet and a poorly proportioned jet are not acceptable. One-sided atomized spray pattern within an approximate 35° angle is acceptable.

If all of the above specifications are O.K., end of test.

If one or more of the above specifications are not O.K., replace injection valve and valve seals.

DAMAGED INJECTION VALVES

To identify damaged injection valves, look for the following:

* Formation of drops

* Cord-like jet

* Poorly proportioned jet

GOOD INJECTION VALVES

To identify good injection valves, look for the following:

* Well proportioned jet

* Slightly one-sided atomization

SERVICE INFORMATION - ENGINE 103 ENGINE

Fig 1: ENGINE 103 ENGINE - STEEL INJECTION VALVES SPECIFICATIONS TABLE

Fig 2: ENGINE 103 ENGINE - BRASS INJECTION VALVES SPECIFICATIONS TABLE

TIGHTENING TORQUE - 103 ENGINE

TIGHTENING TORQUE	NM (IN. LBS.)
Injection lines to fuel distributor (reference value)	10-12 Nm (89-107 in. lbs.)
Injection lines to injection valves (reference value)	Steel: 12 Nm (107 in. lbs.) Brass: 10 Nm (89 in. lbs.)

SPECIAL TOOLS - 103 ENGINE

DESCRIPTION	PART NUMBER
Special Tools	P/N 904 589 00 21 00

NOTE: Before testing injection valves, fill container of tester with clean test fluid (e.g. Shell Mineral Spirits 135) and bleed tester.

CAUTION: Never use normal gasoline or other easily flammable/ combustible fluids in valve tester.

Only injection valves which do not meet specifications must be replaced. Always install new seals when reinstalling the injection valves.

TEST PROCEDURE - 103 ENGINE

Remove injection valves. Before starting the tests for opening pressure, leak and spray pattern, check injection valve visually for dirt or rust. If rust can be seen in fuel inlet or spray nozzle, replace the injection valve. Connect injection valve to tester. Bleed pressure line with shut-off valve open and coupling nut loose. Then tighten coupling nut.

Contamination Test Open shut-off valve. Operate hand lever slowly (2 sec./stroke). If pressure does not build up to 2.0-2.5 bar (236 psi), the injection valve has a leak (e.g. wedged particles). Close shut-off valve. Thoroughly flush injection valve by operating hand lever rapidly until valve is completely flushed. The injection valve is completely flushed when there is no further increase in high pitched chattering sound.
NOTE: On new injectors, the first time opening pressure can exceed the nominal opening pressure.
Opening Pressure Test Open shut-off valve and read opening pressure while operating hand lever slowly (2 sec./stroke). The opening pressure should be between: 3.0-4.1 bar (459 psi) for steel valves or 3.2.3 bar (46-62 psi) for brass valves.
Leak Test With shut-off valve open, operate hand lever slowly. Bring pressure to 0.5 bar (7 psi) below previously measured opening pressure, but not below 2.8 bar (41 psi) for steel valves or 3.0 bar (44 psi) for brass valves and maintain it. No drop should fall from the injection valve tip within 15 seconds (wetness at the tip is normal).
Chatter and Spray Pattern Test Close shut-off valve. Flush injection valve by moving hand lever several times at approx. 0.5 sec./stroke. Reduce hand lever speed to 1 sec./stroke. The injection valve must chatter. The formation of droplets, a cord-like jet and a poorly proportioned jet are not acceptable. One-sided atomized spray pattern within an approximate 35° angle (55° for brass injectors) is acceptable.

If all above specifications are O.K., end of test.

If one or more of the above specifications are not O.K., replace injection valve and valve seals.

DAMAGED INJECTION VALVES

To identify damaged injection valves, look for the following:

* Formation of drops

* Cord-like jet

* Poorly proportioned jet

GOOD INJECTION VALVES

To identify good injection valves, look for the following:

* Well proportioned jet

* Slightly one-sided atomization

SERVICE INFORMATION - 116 (4.2) & 117 (5.6) ENGINE

116 (4.2) & 117 (5.6) ENGINE - INJECTION VALVES

INJECTION VALVES	PART NUMBER
MBNA part number Bosch number	000 078 57 23 0 437 502 035
Opening pressure w/ new valves w/ used injection valves	4.3-4.6 bar (62-67psi) min. of 3.7 bar (54 psi)

TIGHTENING TORQUE - 116 (4.2) & 117 (5.6) ENGINE

TIGHTENING TORQUE	NM (IN. LBS)
Injection lines to fuel distributor (reference value)	10-12 Nm (8107 in. lbs.)
Injection lines to injection valves (reference value)	12 Nm (107 in. lbs.)

SPECIAL TOOLS - 116 (4.2) & 117 (5.6) ENGINE

DESCRIPTION	PART NUMBER
Special Tools	P/N 904 589 00 21 00

NOTE: Before testing injection valves, fill container of tester with clean test fluid (e.g. Shell Mineral Spirits 135) and bleed tester.

CAUTION: Never use normal gasoline or other easily flammable/ combustible fluids in valve tester.

Only injection valves which do not meet specifications must be replaced. Always install new seals when reinstalling the injection valves.

TEST PROCEDURE - 116 (4.2) & 117 (5.6) ENGINE

Connect injection valve to tester. Bleed pressure line with shut-off valve open and coupling nut loose, operate hand lever several times. Then tighten coupling nut.

Contamination Test Open shut-off valve. Operate hand lever slowly (2 sec/stroke). If pressure does not build up to 2.5-3.0 bar (364 psi), the injection valve has a leak (e.g. wedged particles). Close shut-off valve. Thoroughly flush injection valve by operating hand lever rapidly until valve is completely flushed. The injection valve is completely flushed when there is no further increase in high pitched chattering sound.
NOTE: On new injectors, the first time opening pressure can exceed the nominal opening pressure.
Opening Pressure Test Open shut-off valve and read opening pressure while operating hand lever slowly (2 sec./stroke). The opening pressure should be between 3.7.6 bar (547 p5j).
Leak Test With shut-off valve open, operate hand lever slowly. Bring pressure to 0.5 bar (7 psi) below previously measured opening pressure, but not below 3.5 bar (51 psi) and maintain it. No drop should fall from the injection valve tip within 15 seconds (wetness at the tip is normal).
Chatter and Spray Pattern Test Close shut-off valve. Flush injection valve by moving hand lever several times at approx. 0.5 sec./stroke. Reduce hand lever speed to 1 sec./stroke. The injection valve must chatter. The formation of droplets, a cord-like jet and a poorly proportioned jet are not acceptable. One-sided atomized spray pattern within an approximate 35° angle is acceptable.

If all above specifications are O.K., end of test.

If one or more of the above specifications are not O.K. Replace injection valve and valve seals.

DAMAGED INJECTION VALVES

To identify damaged injection valves, look for the following:

* Formation of drops

* Cord-like jet

* Poorly proportioned jet

GOOD INJECTION VALVES

To identify good injection valves, look for the following:

* Well proportioned jet

* Slightly one-sided atomization

SERVICE INFORMATION - ENGINE 104 & 119

ENGINE 104 & 119 INJECTION VALVES

INJECTION VALVES	PART NUMBER
MBNA part number Bosch number	000 078 58 23 0 437 502 054
Opening pressure w/ new valves w/ used injection valves	3.9-4.5 bar (57-65 psi) 3.3-4.3 bar (48-62 psi)

TIGHTENING TORQUE - ENGINE 104 & 119

TIGHTENING TORQUE	NM (IN. LBS.)
Injection lines to fuel distributor (reference value)	10-12 Nm (89-107 in. lbs.)
Injection lines to injection valves (reference value)	10 Nm (89 in. lbs.)

SPECIAL TOOLS - ENGINE 104 & 119

Description	Part Number
Special Tools	904 589 00 21 00

NOTE: Before testing injection valves, fill container of tester with clean test fluid (e.g. Shell Mineral Spirits 135) and bleed tester.

CAUTION: Never use normal gasoline or other easily flammable combustible fluids in valve tester.

Only injection valves which do not meet specifications must be replaced. Always install new seals when reinstalling the injection valves.

TEST PROCEDURE - ENGINE 104 & 119

Remove injection valves. Before starting the tests for opening pressure, leak and spray pattern, check injection valve visually for dirt or rust. If rust can be seen in fuel inlet or spray nozzle, replace the injection valve. Connect injection valve to tester. Bleed pressure line with shut-off valve open and coupling nut loose, operate hand lever several times. Then tighten coupling nut.

Contamination Test Open shut-off valve. Operate hand lever slowly (4 sec./stroke). If pressure does not build up to 3.2 bar (46 psi), the injection valve has a leak (e.g. wedged particles). Close shut-off valve. Thoroughly flush injector valve by operating hand lever rapidly until valve is completely flushed. The injection valve is completely flushed when there is no further increase in high pitched chattering sound.
NOTE: On new injectors the first time opening pressure can exceed nominal opening pressure.
Opening Pressure Test Open shut-off valve and read opening pressure while operating hand lever slowly (2 sec./stroke). The opening pressure should be as follows: New injector: 3.9-4.5 bar (57-65 psi) Used injector: 3.3-4.3 bar (48-62 psi)
Leak Test With shut-off valve open, operate hand lever slowly. Bring pressure to 0.5 bar (7 psi) below previously measured opening pressure, but not below 3.0 bar (44 psi) and maintain it. No drop should fall from the injection valve tip within 15 seconds (wetness at the tip is normal).

If all above specifications are O.K., end of test.

If one or more of the above specifications are not O.K., replace injection valve and valve seals.

DAMAGED INJECTION VALVES

To identify damaged injection valves, look for the following:

* Formation of drops

* Cord-like jet

* Poorly proportioned jet

GOOD INJECTION VALVES

To identify good injection valves, look for the following:

* Well proportioned jet

* Slightly one-sided atomization