XJ 2.5 TD injector no.1 needle sensor repair step by step with pics. After much research today I've pulled apart my injector no.1 with a faulty needle sensor coil and got in to it trying to repair it .
It wasn't that difficult at all and went surprisingly easy , just got to go slowly and keep everything as clean is possible . Here we go ... http://www.ausjeepoffroad.com/forum/...47e570d3e5.jpg Injector has to be pulled apart. The top part should be in the vice and injector body can be undone with a bit of force and a small pipe used as an extension . Make sure fuel returns are not damaged . http://www.ausjeepoffroad.com/forum/...4810c4d381.jpg This is just a close up of separating the injector . http://www.ausjeepoffroad.com/forum/...481ae2ee61.jpg And this is the injector in pieces . Take care and pictures of the order and positioning of each component . http://www.ausjeepoffroad.com/forum/...482ab6c831.jpg Remove the two pins that hold the needle coil terminals plastic cover using a pointy puncture tool . Place the injector in a vice in an angled position so the fuel return hose nipples are not damaged . http://www.ausjeepoffroad.com/forum/...483da3d3f5.jpg This is how pins should come out... http://www.ausjeepoffroad.com/forum/...48460df89d.jpg Once the pins are removed the terminals cover just comes of with no effort at all ...maybe just a gentle pray to separate it from the injector . http://www.ausjeepoffroad.com/forum/...4853591158.jpg Unsolder the two wires (very important) and try to leave just a smooth solder surface on the terminals . The plastic part where the terminals sit can be removed gently to make it easier to pull the coil out . http://www.ausjeepoffroad.com/forum/...4864c393cf.jpg There will be a washer that maybe sticks to the coil inside and remove it (unless already fallen off). Use a screw and gently try to screw it in the hole that holds the coil by hand first than with a philips screwdriver gently a little bit more untill it grips . Watch the coil terminals and if they start to move than stop. With the help of a side cutter gently pray out the screw and coil should slide out . Make sure the size of the screw is not to big . Has to be just enough to grab otherwise coil can be damaged . http://www.ausjeepoffroad.com/forum/...4897bba7a4.jpg And this is the needle sensor coil removed . http://www.ausjeepoffroad.com/forum/...48a5ec96ea.jpg Managed to find the break in the coil wiring after just 8 turns removed and decided that shouldn't be an issue if I just use the good end and resolder it. http://www.ausjeepoffroad.com/forum/...48b5f80e40.jpg Had to use an Aspirin tablet to remove the clear laquer from the wire to be able to solder it back.... it is so fragile , breaks very easy . I think I should have just rewire the thing with new copper ....Maybe due to heat the existing copper wire looses from its elasticity and breaks much easily....time will tell . It has 98 ohms reading when measured and that is pretty good in my books . Pretty much that is all . Take care when putting it back all together . Just take your time . http://www.ausjeepoffroad.com/forum/...48e317d693.png And this is the pulse out of the needle sensor coil viewed on an osciloscope . It wasn't to hard after all ...and thanks also for the other members that have help with suggestions ... The following link shows the same testing with an android phone or tablet . http://www.ausjeepoffroad.com/forum/...d.php?t=154725 Download Android application from : https://www.apkmonk.com/app/com.mycompany.oscilloscope/ Doesn't seem to be available on Google Play anymore . |
Its great to learn something new!
I was lead to believe that the coil had to come out the top. How wrong was that! I have a crook one here & some time I may try & fix it. Thanks greatly for your detailed post. |
this has been shared to the vm au fb page :)
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Great post Amlav!
Should be sticky and should be on VM original manufacturer' FB page and group! R |
added the link for the Android application .
Here it is : https://www.apkmonk.com/app/com.mycompany.oscilloscope/ |
Well done, how does the aspirin remove the lacquer?
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