Here is the link to the pdf I was talking about.

http://www.dieselpro.ca/Poppet%20Valve.pdf

 

Thanks for the visual Grant, So run torx screw down to gain the clearance needed.

 

Swapped the whole injector, or just the solenoids? I guess #3 is not buzzing now or discharging any oil while runnig but #1 seems to be fine again?

Sounds like it's time for a new injector.

 

Yeah swapped entire injector, and symptoms followed. These are new in March, so I maybe before tearing too far I should find out what Casserly's warranty covers.

 

If the screw is broken then you could simply replace it if you can get the broken piece out and can locate a replacement screw. I just looked at my photos...it's not a torx or allen drive but more like the teeniest hex head bolt that you ever saw. Maybe a 4mm socket?? I think I have the special driver for that screw in my toolbox somewhere...I'll try and find it to see what the size and shape it is.

If the screw is loose then you can try tightening it. You just need to make sure the poppet valve is indexed correctly. I can explain how to do that if you need. I'll PM you with my cell phone in case you discover a loose or broken screw.

If you pull the solenoid and everything looks good then you might need a replacement injector. Sometimes the nozzle spring breaks and that part is wayyy down in there so it's not something that could be fixed on the side of the road. Would be easier to just replace the injector at that point.

Could also be a bad solenoid. Swapping solenoids would ensure that your problem is mechanical and not electrical. I'd try that while you are in there. It's pretty simple to swap solenoids, you just want to make sure you swap them back to their original spot when you are done trouble shooting because there could be minor clearance differences between injectors...especially as they age and wear down.

Good luck!

 

Pretty sure he offers an 18 month warranty. Give him a call tomorrow.

 

Sounds like you got it figured out. According to the pdf the codes would not show up if that was the problem. I'm not sure where that came from. It looks maybe like a service bulletin that someone may of modified.

 

Pulled the solenoid now on 3 plate will spin loosely, my screw is a torx screw Greg, I'll fix it if it's as simple as tightening to a gap of .004

 

Impatient...tightened screw with .004 feeler underneath, buzz test passed, no codes, nice loud crisp buzz. Now to try to run it in a bit(thawing out)

 

Tighten it all the way and then check with feeler gauge. If you simply tighten to .004" then it will get loose immediately and back to square one.

Make sure you index the poppet. You will need the spacer off to do that.

 

Guess I will be calling you Greg.

 

Just use some Gorilla glue or locktite.

 

Well thanks to all of you who offered advice, when I initially started the thread, I was also pricing IDM's after clocking my poppet correctly after Greg's advice, and Grant's pics, initially deciding to go in deeper after Chris questioning injectors, NO CODES PRESENT!!!

Thanks again, reps to all that I can, I apologize if I have to spread it around (Greg)to those who I can't get.

 

I love a happy ending!! Glad it worked out good.

 

Glad you got it running. How does it run? Nice and strong?