OM648 Injector Refurbish | Changing the Nozzles! 

VERY VERY IMPORTANT to tell everyone that the first step is for the engine to be at working temperature before attempting to remove the injectors. Some folks might skip your complete video before attempting removal!! Great detail and I love your videos.

Just a quick tip. I had an injector stuck so bad , I just decided to take off the keeper clip off . I drove the car 5-10 miles to get it hot . It sounded like a train driving with the blow by of the injector, but It came out like butter when I brought the car back for removal . Not the best way to do it but It worked great !

Super video, on Injector removal & rebuild. I will keep checking this over & over !!

Lapping trade tip - use a figure 8 pattern rather than a single circular motion. This will balance out the natural favouring of pressure on one side to a balanced all round surface lap.

You are the only video instructor that says not to remove the needle from the nozzle. All other videos show the needle being removed and cleaned.

Thank you for video on Ultrasonic cleaning of injectors !!

Hi @MBDieselFreak, thank you for very informative video, I have an OM647 5cylinder 2.7 cdi with injectors banging like crazy, it has done 480k kilometers. I found new nozzles for them, bought the new copper shims, new clamps and new bolts. I'm going to give it a try at rebuild. Wish me luck hehe

Nice video, thank for doing an share it. Only few things are bit confusing for me: - why you didnt just replace the nozzles with new ones? There are sets for sales with about 50-80e(have no idea in GBP currency) per one, and then for about 1.5-3e/pcs you get the O-rings and the copper shim at the end are something as 3-6e/set of 4(or at least for my car with 4cyl and BOSCH injectors they cost that). Then you give it to some bench test to se how the flow is. (you mention some bosch service place) - ultrasonic bath : For petrol injector with 3-3.5bar rail pressure, "huge" 2-4 holes and no pressure at all against the nozzle , maybe there is some logic to use ultrasonic cleaning. Diesel, from other hand with pressure inside the fuel system of 300-1800bars, microscopic holes for fuel dispersing and inside cylinder working , do you think that ultrasonic cleaning will make some differences? I`ve seen that before and still have no logical explanation for it.. From other hand, if the nozzle holes get clogged and /or the needle get worn then the injector work bad, and again the nozzle replacement with new one will fix the issue. - the surface you clean with sand paper are grinded with proper machine, stone disk and they are with exact angle. How you can be sure that you make proper 90° compared to the inner center axis? Also, both parts are tight together, so how there must be some debris, damaged surfaces and so on.. Sorry, I work as metal and CNC engineer and cars are may hobby, but that are some confusing advises for me I see here.. Also, I presume the tightening torque for the nozzle cap is 70-75Nm. At least for similar Bosch looking and size is same. And need to be mentioned that is fine thread so need to be sure nothing is over it when fit on place. dieselcatalog.online/en/bosch/04451/0445110320.html - that is for my car`s injector but maybe can be helpful for others to find their spare parts. At least so far I found the nozzles and the o-rings, what I`ll like to replace.

Do you have any idea if the OM611 injector nozzles are smaller in spray pattern holes compared to ones from OM648? Thanks a lot!

If you set the injector in a block you cab control it better when lapping ,this will keep it upright and level

Nice video. I like your style! Nitpicks: during injector installation I like to finger tighten the fuel line back on prior to bolting down the injector. This gets the injector clocked correctly and prevents straining the fuel line. I also counter-hold the injector’s fitting with a second wrench; not always necessary but I don’t like to push my luck.

Great video, when you clean the nozzle and body could this temporary fix my leaky injectors because you are removing material from the nozzle and body of the injector .

Nice video. I would call it “diesel injector heart surgery”. You did not comment on the need to change the little o-ring on the return line connector. Also having a tweezer would help working with gloves on. Very informative.

Very helpful video! Cheers

Regarding the part number for the injectors. If I have a cdi 2-20 injector where can I find that part number

what liquid are you using in the ultrasonic cleaner? Nice tutorial .

i want to change the nozzles on 4 om611 injectors to c30amg nozzles, do you think i should mess with any of this like cleaning or lapping? the injectors are running good until now.

What you think my friend ! I have a c270 and im already put on a bigger high pressure pump and turbo. Im planing to change my injectors nozzle to the c30 AMG-s . Can it work ? I seen the whole injectors got chenged but what you think about just the nozzle?

Hi there! I have an OM642 and I tried to remove one of the injectors and somehow I managed to break the return line of a nearby injector. It didn't fall, but it's bent and I'm afraid I messed up very bad and I need a new injector. Any chance of changing that top part? Also, are you buying new nozzles for the injectors or just cleaning them? Thanks a bunch:)

When you did the lapping how do you know you didn't introduce contaminants into the needle?

Do they make replacement injectors tips for the 0.8L cdi smart

Thank you for the video, very much appreciate the videos. What would be really nice is to be able to increase the flow rate of the injectors. I already have some C30CDI injectors but would like to check the flow rate. Any thoughts on how we could do that in a DIY fashion? Flow rate is something that would be great to check even with stockers. Also I like the brass return line fittings, so much nicer than the stock plastic ones. I replaced mine a long time ago.

Awesome video, thanks for posting it up! Will be tackling this project in 2 weeks or so, whenever the new nozzles come in. What is your choice for a solution in the ultrasonic basin? I know you said in the video diesel works great, but do you have a preference in any industrial cleaners/degreasers?

are the om642s rebuildable? they seem very similar for all intents and purposes, could you include link for rebuild kit?

Good job and excellent mechanic 👍

Can a high return flow be caused by faulty injector nozzles?

I taught that this was simple, but its way to much small risky parts that i need to care about, Bosch Diesel specialist will be my friend right there

Awesome video!! I just had a question though, about how the vinal tubing is there to protect debree, dirt of liquids getting into the injector. This is at 8:10 If a small amount of debree or dust actually got through that hole, would this be catastrophic? Can the injector be cleaned out/repair??

I don't have that 11:39 little shim on my Chevrolet multijet 1.3 injector, everything else is dead same, did I loose mine? Or is it different??

The bolt holding the injector clamp down is a stretch bolt and should be replaced after removal.

Perfect video thanks

hi:) I have a bosch commonrail injector part № 30750283. Would you please tell me how much (Nm) tightening torque to tighten the nozzle?

Don't forget to install the copper ring at the bottom of the injector.

Have you ever come up with a way to do lubra moly diesel flush on an om648 common rail??? thx

I have a 2005 Cdi with 9500 original miles. There is a bit of what appears to be fuel on the foam around the injector closest to the firewall. Should I suspect the oring at the top of injector. These have never been touched Thanks I have only ever replaced the brake fluid and a few oil changes. And both batteries. Going to do fuel filter and coolant change shortly. Anything else for preventive service?

I suspect I have one or more injectors leaking fuel (NOT blowby leak/black death) into the cylinder causing excess exhaust smoke. Will replacing/cleaning the nozzles fix this, or is a leak problem higher up in the injector valves necessitating full replacement? (06 E320 w/ 275k mi)

Thanks for the video! I love the om648, my absolute favorite engine. I rebuilt the injectors in my old 7.3 and it was a breeze. It's ashame these can't be totally rebuilt DIY but I get it. Mine are fine now but I know the day will come when I have to do this or slap on some rebuilds. I had a 06 e320 cdi with 425k on it before some bimbo pulled out in front of the wife and totaled it. We replaced it with an 05 of the same make and model and it currently has over 300k. I know it won't be long now. These engines are tanks. Love the pre DPF engines. Thanks again, very helpful. Btw, did the lapping seal it up this time or did you have more problems? Hope it went good. Chris

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What do you use when putting the injectors back together? Diesel or assembly oil?

Hi what cleaning fluid do you use please

Can you give me a suggestion? I posted this on a forum but no advice yet: I am not knoledgeable enought and sorry to call it misfire for a diesel. it is actually like a hiccup and it feels/sounds like an explosion. Thought it has something to do with the combustion. Dealer wanted to change 3 injectors for bad values but not specific codes quoting me at $2800 before tax. Other mechanics recommendations were injectors as well. Therefore I had my Indy changing some of the injectors today with no change. As short history car has 166k miles and this started at about 164k miles shortly after and around or at about the time of adding freezing additive for diesel fuel while a tank fill up which could be just coincidence. Egr code has been on and off rarely every now and then for the past year...about 35k miles. Lp fuel pump in tank replaced at about 145-150k miles. Shortly after at about 155k miles fuel filter changed. No start up problems, no smoke like when bad injectors. No hiccups for the first 5-10 min when cold. Then thy start randomly intensifying in frequency with the warmer the engine gets, but also sound/feel of the hiccups/explosion/detonation intensify itself as well. The fee is more like a skip of something like a big heavy chain from a gear to another. It also sounds/feel like a gun intermittently shooting one round then within a second 2-3 rounds then one more or 2 seconds another 2-3 rounds. It gets overrided when accelerating and the feel/sound of the hiccup/explosion/detonation reduces with higher RPM to the point of when reaching anything above 1500 it seems like it’s goes away or it is not there anymore. Could it be the High Pressure pump? Could it be my EGR stuck closed/opened influencing the intake with high temp exhaust gases recirculating since it starts to be more pronounced warming up and it is never there at cold start? Please let me know if anyone experienced anything similar or what else you guys may think of.

Thanks so much

Did the injector leak and puddle on the cam cover around the injector?

Very good video thanks

I have the same problem. Where exactly is the number 4 fuel injector if you are looking at the engine from the front of the car?

Have you got ANY tips removing the injector bolts that SNAP of below the head line... 3 bolts just sheard on me and now renders the van useless. I have about 5cm of thread left in the head and no purchase on the thread. What is the best way to remove the old snapped bolt on this occasion. I would guess, 6mm diameter copper pipe used for a brakeline. Cut to length of what ever gap is left from bolt to flush of head. Insert the copper pipe into the broke hole bolt. Weld what ever you can INSIDE the copper pipe stacking the weld pool. The weld at the very top an fallen key or screwdriver (sacrifice tool). Then use the welded heat to remove the bolt.??!!

hi does these need reprogramming sometimes? tia

I have a 2005 E320 CDI with 120K miles on it. Because I like this car so much, I am considering replacing all 6 injectors as a preventative maintenance. I have a couple of questions I hope you can give some advice on: 1) would you advise doing this as preventative maintenance? If I use om648 injectors (as opposed to om647), do I have to do any re-coding (I don't have a STAR). If I used the om647 injectors, does it require recoding with STAR? Thanks in advance!

Where can I go to learn to rebuild these injectors

I liked the videoz Found it useful HOWEVER There’s something bothering me! When you start rubbing the nozzle on the sandpaper wouldn’t it get filled up with small dust particles from the grains that come off the paper? 🤔

This is an excellent and very educational video, i have a question which is "what if some of the micro wholes in the nozzle are blocked?"

Nice video plzz sir more assembled video injectors

Hi Ross! Do you happen to know if switching over to the C30 AMG injector nozzles is enough to get more fuel into my cylinders or if there are any other significant differences between the OM646/7/8 injector and the C30 AMG one? I'm trying to get a little bit of extra power out of my W211 E270 CDI (without making it roll coal of course, I hate seeing cars smoke on public roads) and the nozzles would be significantly easier to find (and cheaper) than 5 whole injectors.

Bro can you help me with procuring new nozzle tip. I am from India but India new Noozle is not available only Chinese duplicates are available.

Hey I know this is about a year old, but I put all 6 injectors new into my 2005 e320 cdi. And I was wondering if I needed to do anything to the injectors. I have a mb dealership about 45 mins from me. But as anyone I avoid going their because I feel taken advantage of when I do. And I also have found anything online saying that there is anything else I need to do. I replaced the copper washer and retaining bolt. Also I put on a new fuel filter. But do I need to ge the injectors matched to the ecm.?

Nice video. Where can I purchase the nozzle.

Thank you :)

You did very good yob but there is one thing that is interesting. Yous sad to not remove needle from nozzle to avoid anything to get in there also you did sanding on that nozzle and put it on the angle in sonic cleaning process. As nozzle is on the angle there is possibility of dust, debree and tiny metal pieces to remain between needle and nozzle body. Is it better to remove needle and set everyhing in sonic process with nozzle body (directed up) and needle to remove all dirt and debree?? Overall thanks a lot on video!

How about liwei nozzle injector?

Maybe your cofie filters are doing some obstructions in ultrasonic cleaning

amd after rebuild the spray pattern is little bit different and the injectors need to go onto a test stand, to create the new injector codes, for programming your injection control module. Otherwise they won't work perfectly

Do you have to reprogram the injectors after

That's not a crowfoot wrench... that is a line wrench... A Crowfoot wrench is just the very end of a line wrench with a square hole in it for a 3/8" extension.

DID THE RE-LAPPING WORK TO STOP YOUR SEEP?

Very interesting ? your the only person saying they have a leak between the nozzles and the body . How does this factory machine surface wear ? Why is the high pressure fuel not lifting the needle off the nozzle seat to spray fuel into the engine as it is designed to . It only has to overcome the force of the small spring at the base of the needle . The needle is safe to remove from the noozle to clean .

thank you sir for the video, i currently have an issue with my C270 CDI (OM612 engine). the car cuts off the engine upon hard acceleration, i have replaced the high pressure fuel pump and had the injectors "refurbished" from an injector service center but i still have not come right as yet. the car now cranks but doesn't start. Can you assist as to what the problem might be?

Removing the common rail tubing with a LINE WRENCH, its is not a crows foot.

Spot on.

Iv seen that some guys have a cutting tool they use on the head before reseating the injector.

I’m a bit lost here. You say you won’t put the nozzle on the sonic cleaner all the way so you don’t get dirt stuck in. But you’ve just sanded the nozzle and body. So that’s sand and metal all over the nozzle and body in the parts you say not to get anything in.

Everywhere on forums I see that om613 came with solenoid injectors and om648 came with piezo injectors, but I haven't been able to find a definitive answer whether 648 injectors are actually piezo. The injector internals are absolutely identical from om611 612 613 and om646 647 648. MBDieselFreak do you know or anyone know for sure?

I would never get sandpaper anywhere near my injectors

Video dobré jen mám dotaz. Těsnění tam dávat nemusiš?

actually i would not recommend doing the lapping cause by hand will never be as "clean" as you need it ... imagine 2000 bars of presure moving through the injector ...

Got a injector test bench

👏👏👏👏

It's the black arts I tells ya!

Nice

Looking at this video...I'm not going to attempt it ..i don't have the skills in my hands for small parts like that.

Pour nettoyer la glace du porte injecteur,j'utilise la cendre de cigarette.

torque it to 50 ft lbs and use some locktite on the thread 👍

32 foot pound is the torq for the nozel -

Why you call it changing the nozzles when you don't change them? what's the point of doing all what you do if you don't change the nozzle?

🤝✊☝️

Like

1:02 Its on too tight how did you loosen this? Didn't see you use a vice or clamp? Are you just a brute? Lol

OM 648? haha tiens un moteur que je ne connais pas !lol

i get too much leak by so i buy a refurbished set, they last a year if im lucky then to much leak by again. it would be nice to have one of these injectors last long enough to consider new nozzles . other diesels knock out hundreds of thousands of miles without being touched. yet these injectors have the lifespan of a spark plug. edit. no. thats being mean to spark plugs

Torque spec = FT

Jolene

Ur better then Alex.

45 up 50 foot-pounds

Like n sub

Would be good video if he check the view area, half what he was pratting on about was hidden, spoiled it for me,

It will be a lot better if you can show wat you are really doing, by moving your camera in the proper position. The rest is ok.

Not even a microscopic dust can go in.....gets a freaking sandpaper.....

"Simple", not "simplistic".

In the beginning, you are doing one thing while talking about another. Honestly very informative but too much philosophy at the expense of technicality.