Bosch injectors issue

[raziel]

Bosched the car 2 monts ago and until today drove the car with lucas injectors. Everything was fine but there aren't power in higher rpms. Changed the injectors and when start the car was working roughly and cutting out. Pull the pump towards to reduce the advance and there was some minimal change but still cutting out. When i drove the car runs fine in higher rpms like before with the lucas pump but about 1.5 - 2K rpms there was sound from the injectors like there is too much advance.
Took off the injectors and tested them in my friends garage. The breaking pressure was about 210-220 bars and the nozzles seems fine.
Is there anyone that tested the bosch injectors breaking pressure because there are two stamps on them - one is 175 bar and the other is only with numbers (218) ? Any other ideas for cutting out issue?
Put the lucas injectors back and all was fine.

Sorry for my poor english

[Tom]

I thought bosch injectors were supposed to have a break pressure of 175? So surely if yours have a break pressure of 220 they are completely f*cked? Im just thinking aloud really :p

[raziel]

I tested six injectors and the breaking pressure on all of them was the same and i am thinking that if all of them are screwed the breaking pressure must be different. The pop tester measurement scale is in atm but i dont think there is huge difference. If i change the shims on the injectors can i calibrate them with normal pop tester or not?

[zx_volcane]

Yeah standard break pressure is 175

If its any higher it'll take longer for them to pop, ie same as retarding the timing - theoretically you'd need a bit more advance to compensate.

You also get more a diesel clatter from high breaking injectors, they're noisier.

Sure your pop tester is reading right? Bit weird if you've got 6 injectors breaking at 220.

[raziel]

Yes i notice that the car is a bit noisy but its cutting out on idle too. When it start is fine and after 4-5 seconds the cutting out begin. The advancing is now just like oem - in the middle. For the pop tester i am not so sure but think to take off one of mine injectors and test the pop tester because mine lucas one are perfect or go to local garage and calibrate the bosch one but i wasn't sure what the breaking pressure is.

[dalishare]

Yes i notice that the car is a bit noisy but its cutting out on idle too. When it start is fine and after 4-5 seconds the cutting out begin. The advancing is now just like oem - in the middle. For the pop tester i am not so sure but think to take off one of mine injectors and test the pop tester because mine lucas one are perfect or go to local garage and calibrate the bosch one but i wasn't sure what the breaking pressure is.

The injection order is not same between bosch pump an lucas pump you must invert metallic pipeline between injectors and pump or use the bosch ones.

[Piggy]

I would think he had already done this as it wouldnt run at all on the bosch pump.

break pressures are the issue here I would think

[raziel]

Called one guys and tomorrow will went to local garage to change the shims and calibrate them. Will write what's going on. The price here in Bulgaria is £2.60 per injector for calibrate and £0.43 if you want only to test it.

[Anton]

Damn! Can i post you some injectors?

[raziel]

I think that the shipping would be pricey than the testing

[Anton]

Probably still cheaper!

[Tom]

That is dirt cheap. Unless of course you can buy a tv for £3.00 over there?!

[raziel]

No i cant buy a tv for £3 of course . Most of things here are expensive than other EU countries.
Checked the Royal mail shipping and its £7 for 5 days delivery
Last week bought some parts for the car:

timing belt
auxiliary belt
all of the belt tensioner pulleys (without the body and the damper of the one that comes with a/c Pugs because i refurbished it)
lower engine mount (the bigger one)
wishbone P bushes fitted on Partner
5 litres engine oil Total
fuel filter
air filter
oil filter
cam seal

total: £165

Tell your opinion. Next time i am considering to buy parts from UK.

Tomorrow will went to the local garage because use this car every day and yestrday broke the little thing on the injector that connects it with the leak off hose and i block the leak from the last injector with wooden stick but still gets air in there and today first start was very rough.

[raziel]

Injectors calibrated and one refurbished with new nozzle. Now working like a charm

[Anton]

£7 for postage is cheap, i'd gladly send you a set out! Or if you had a set spare....

BTW those prices seem about the same as over here.

[zx_volcane]

Injectors calibrated and one refurbished with new nozzle. Now working like a charm

Glad you sorted it !

£7 for postage is cheap, i'd gladly send you a set out! Or if you had a set spare....

BTW those prices seem about the same as over here.

Anton, my local diesel shop will calibrate a set of injectors for a tenner, turn around is prob quicker too!

[Anton]

Tom you are the man who knows!

[zx_volcane]

TBH any diesel shop should do it for that price, its not going to take them 10mins to pop test, and re-shim if necessary

[raziel]

No i dont have a spare one. Just have 2 injectors with screwed up nozzles. That said the mechanic. Adjusted the breaking pressure to 180 bars and said that's better but i dont think so because car started just a little roughly. Tomorrow i will play with the advancing of the pump and see whats going on.
Have another problem that make me crazy and defo is boost leak. Make only about 9 psi on full boost. I had tightened the allen key bolt on the turbo four turns and seems to be a little difference but gauge still saying 9 psi. Tomorrow will check the D seal and pipes. Could it be the hose that comes from the egr valve and going to the little vacuum valve with green plug behind the battery because i am sure that is ragged.