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New Bosch India 6.5 turbo injectors

the gauge that comes with the low cost testers almost always suck.
You can replace the gauge with better ones- and if you want get ones that have two needles - one shows live and the other gets pushed to peak and stays there- see pic. Note I am not saying use this brand gauge- just a random example found online quickly.

You can also get a pressure retention valve like a compression tester uses that holds peak until you release it.

You can also get digital gauges that record peak.

Doing it on the cheap- put your phone video recording on slow motion record and test it. Then play back. But realize you need a few cycles and have to learn to pump the handle properly. Like learning to use a feeler gauge- it is not hard but takes a little goofing with it is get the feel.
IMG_2926.png
 
Will L. said:
the gauge that comes with the low cost testers almost always suck.
You can replace the gauge with better ones- and if you want get ones that have two needles - one shows live and the other gets pushed to peak and stays there- see pic. Note I am not saying use this brand gauge- just a random example found online quickly.

You can also get a pressure retention valve like a compression tester uses that holds peak until you release it.

You can also get digital gauges that record peak.

Doing it on the cheap- put your phone video recording on slow motion record and test it. Then play back. But realize you need a few cycles and have to learn to pump the handle properly. Like learning to use a feeler gauge- it is not hard but takes a little goofing with it is get the feel.
View attachment 92528
Click to expand...
IDK if @dbrannon79 got the threads and size figured out so He could get an adapter to something like pipe thread and a better gauge can then be installed.
I do bieve that He did install a secondary gauge that might be more accurate.
 
I believe the gauge has 3/8" male BSP straight thread. I never was able to get an adapter to go to regular pipe, but ended up using one of the 6.5 injector lines that was cut in half, coupling it together with a hydraulic tube compression fitting Tee that had female pipe thread. used a 3000 psi gauge on the Tee that seems to work much better.

pumping it up with an injector to test, the tester gauge must have some sort of restrictor inside it to make it move slowly. it will hit maybe 1500 PSI when the gauge I added will reach around 2000 psi. you have to have a quick eye to catch the peak pop pressure.

Here is were I show what I have done. but I would say read the entire thread.

6.5 Diesel Injector Rebuild

There was no issues with hard to start or anything else ? If not then that might be the direction that I am headed. They seemed absolutely perfect.
www.thetruckstop.us
 
OK, I got my sets of these injectors and I have an idea of what’s going on. Barcode stickers clearly show Bosch Made in India. They also show a manufacture date of 08/19 and an expiration date of 08/23. I wondering if these were from the production years in which they had quality problems which led to failures?


IMG_7413.jpegIMG_7414.jpeg

I put a set from Leroy in my ‘99 about 3 years ago, but did not note the date of manufacture. I ran them about 12K miles until my engine failed due to a worn oil coolant line causing loss of oil pressure. Paveltolz had Bill Heath test those injectors and at least 2 had problematic streams of fuel upon pop testing. The rest were passable. I still put new injectors from Quadstar into the new engine.

Would be interesting to hear what were the problematic years of production and the specific parts that were the problem.
 
Big T said:
OK, I got my sets of these injectors and I have an idea of what’s going on. Barcode stickers clearly show Bosch Made in India. They also show a manufacture date of 08/19 and an expiration date of 08/23. I wondering if these were from the production years in which they had quality problems which led to failures?


View attachment 92588View attachment 92589

I put a set from Leroy in my ‘99 about 3 years ago, but did not note the date of manufacture. I ran them about 12K miles until my engine failed due to a worn oil coolant line causing loss of oil pressure. Paveltolz had Bill Heath test those injectors and at least 2 had problematic streams of fuel upon pop testing. The rest were passable. I still put new injectors from Quadstar into the new engine.

Would be interesting to hear what were the problematic years of production and the specific parts that were the problem.
Click to expand...
I wouldn't trust any of them. Test and balance them all.
 
I purchased two sets of these injectors and I’m having them tested as we speak. First off, one injector is missing. These have sat on the shelf in the box they arrived in, individual injectors in their boxes most unopened and inside the injectors were sealed in heavy plastic bags. Why one injector was missing, who knows, but I’ll do some searching in the garage.

One injector had rust and some slag that came right off with a wire brush. It was sealed in the heavy blue bag.

IMG_2521.jpegIMG_2523.jpegIMG_2530.jpegIMG_2531.jpeg

One injector popped at 2000 psi piss and shot a stream, but no chatter. This one needs a new nozzle and possibly a new pintle or just gets replaced altogether.

The rest of the injectors popped at 1950 psi and exhibited good spray patterns. A tear down revealed they were legit Bosch India injectors. So it sounds like I need to buy two new injectors to complete a second set.IMG_2533.jpeg
 
I helped pop 15 of BigT's yesterday while visiting with Bill Heath after a run down to NV to help recover a DMax. Long story, different thread.
IMG_2482.jpeg
IMG_4878.jpeg

Injectors. As far as I can remember from campfire stories, these came from the years when Bosch Germany was forced to have a come to Jesus meeting with Bosch India over a mass purchaser’s discovery of a 40% fail rate prior to use (pop pressure consistency, spray patterns, chatter quality) so I was a hot mess from these. Fortunately, not the case.
First off, I apologized profusely to BigT as I didn’t count the number of injectors in the box and didn’t realize there wasn’t 16 in it. I thought I’d misplaced one but, that area of the shop was relatively organized and after much searching…I didn't find the 16th one laying around nor, an empty box. I'm really hoping he has the one AWOL injector hiding in the garage.

Results, IIRC (they are boxed up in the back of the car right now), 9 popped at 2000, 5 popped at 1950psi and one at 1900. All but one had very good spray patterns and good chatter. A few chattered a little better than the others but, there’s always a few brown nosers in every group trying to stand out. The one with bad spray (streaming vs misting only) and no chatter still popped high (2000?) but, pissed at first.
IMG_0499.jpeg
And then it opened up and sprayed in streams.
IMG_0500.jpeg

The pissing was probably my building pressure up before a full pull on the tester.

A good deal of time was spent trying to get another nozzle and pintle combo to work in this injector body but, even when we found a set that worked in its original body, it wouldn’t perform in the new body which is, beyond scientific exploration, worth. Unfortunately, with only used injectors to rummage through for a better functioning nozzle and pintle, we couldn't correct the problem.

As BigT said, one injector body had a plethora of rust on the threads and what seemed like thread damage (looked crushed in a few spots on initial inspection). The box for it, like all the others, looked like it might have gotten damp at some point but, the paper all the sealed in plastic injectors were wrapped in was dry, showed no signs of any moisture and the plastic wrapper the rusty injector was in was undamaged with no signs of impacts, holes etc. But, as you can see, a good wire brush cleaned things up which surprised me as it looked like it would take some filing or maybe running it through a die(?) to clean up the threads.

In my opinion and I’ll quasi quote Bill, for the price payed, Hell of deal. Now to find injector 16….
 
Caught a couple of typo’s above and the time limit has passed for going in to edit things.
Change: “I was a hot mess from these.”
To: “I was expecting a hot mess from these”

Change: “…it wouldn’t perform in the new body which is, beyond scientific exploration, worth.”
To: “it wouldn’t perform in the new body which is, to me, beyond any scientific explanation or speculation.”

Shouldn’t post at night when I’m tired and have been driving in an unexpected snow storm for a couple of hours.
Good night!
 
Paveltolz said:
I helped pop 15 of BigT's yesterday while visiting with Bill Heath after a run down to NV to help recover a DMax. Long story, different thread.
View attachment 98813
View attachment 98810

Injectors. As far as I can remember from campfire stories, these came from the years when Bosch Germany was forced to have a come to Jesus meeting with Bosch India over a mass purchaser’s discovery of a 40% fail rate prior to use (pop pressure consistency, spray patterns, chatter quality) so I was a hot mess from these. Fortunately, not the case.
First off, I apologized profusely to BigT as I didn’t count the number of injectors in the box and didn’t realize there wasn’t 16 in it. I thought I’d misplaced one but, that area of the shop was relatively organized and after much searching…I didn't find the 16th one laying around nor, an empty box. I'm really hoping he has the one AWOL injector hiding in the garage.

Results, IIRC (they are boxed up in the back of the car right now), 9 popped at 2000, 5 popped at 1950psi and one at 1900. All but one had very good spray patterns and good chatter. A few chattered a little better than the others but, there’s always a few brown nosers in every group trying to stand out. The one with bad spray (streaming vs misting only) and no chatter still popped high (2000?) but, pissed at first.
View attachment 98809
And then it opened up and sprayed in streams.
View attachment 98812

The pissing was probably my building pressure up before a full pull on the tester.

A good deal of time was spent trying to get another nozzle and pintle combo to work in this injector body but, even when we found a set that worked in its original body, it wouldn’t perform in the new body which is, beyond scientific exploration, worth. Unfortunately, with only used injectors to rummage through for a better functioning nozzle and pintle, we couldn't correct the problem.

As BigT said, one injector body had a plethora of rust on the threads and what seemed like thread damage (looked crushed in a few spots on initial inspection). The box for it, like all the others, looked like it might have gotten damp at some point but, the paper all the sealed in plastic injectors were wrapped in was dry, showed no signs of any moisture and the plastic wrapper the rusty injector was in was undamaged with no signs of impacts, holes etc. But, as you can see, a good wire brush cleaned things up which surprised me as it looked like it would take some filing or maybe running it through a die(?) to clean up the threads.

In my opinion and I’ll quasi quote Bill, for the price payed, Hell of deal. Now to find injector 16….
Click to expand...
Well done. Thanks Paul.

I looked around the garage, but could not find the 16th injector. I’ll keep looking. I’m just relieved I got the shudder upon braking corrected. Next up is replacing thermostats. Then my ABS should arrive by Monday and I’ll have Wayne at Eagle Watch Automotive install that and go through the transfer case shifting.
 
Big T said:
I purchased two sets of these injectors and I’m having them tested as we speak. First off, one injector is missing. These have sat on the shelf in the box they arrived in, individual injectors in their boxes most unopened and inside the injectors were sealed in heavy plastic bags. Why one injector was missing, who knows, but I’ll do some searching in the garage.

One injector had rust and some slag that came right off with a wire brush. It was sealed in the heavy blue bag.

View attachment 98799View attachment 98800View attachment 98801View attachment 98802

One injector popped at 2000 psi piss and shot a stream, but no chatter. This one needs a new nozzle and possibly a new pintle or just gets replaced altogether.

The rest of the injectors popped at 1950 psi and exhibited good spray patterns. A tear down revealed they were legit Bosch India injectors. So it sounds like I need to buy two new injectors to complete a second set.View attachment 98803
Click to expand...
Sorry to hear Big T.Hoping to test my 2nd set today.I’ll have to pick up some extra fuel today to see how things turn out with this second batch.
 
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