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-   -   XJ 2.5 TD injector no.1 needle sensor repair step by step with pics. (http://www.ausjeepoffroad.com/forum/showthread.php?t=154680)

amlav 08-01-2019 09:53 PM

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 .

layback40 09-01-2019 06:35 AM

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.

mud_slut 14-01-2019 04:57 PM

this has been shared to the vm au fb page :)

croitoru 14-01-2019 06:01 PM

Great post Amlav!
Should be sticky and should be on VM original manufacturer' FB page and group!
R

amlav 14-01-2019 09:52 PM

added the link for the Android application .
Here it is :
https://www.apkmonk.com/app/com.mycompany.oscilloscope/

CJ6np435 15-01-2019 05:29 PM

Well done, how does the aspirin remove the lacquer?

amlav 15-01-2019 06:01 PM

Quote:

Originally Posted by CJ6np435 (Post 1644781)
Well done, how does the aspirin remove the lacquer?

Don't know exactly how but is an old trick and it works . Hold the wire on top of the aspirin and put the soldering iron tip on the wire and check a few times if the solder from the tip gets on the wire .

croitoru 20-01-2019 02:47 PM

Quote:

Originally Posted by CJ6np435 (Post 1644781)
Well done, how does the aspirin remove the lacquer?

..I guess with soldiering iron applied to , aspirin tablet underneath, laquered wire in the middle, solder iron tip on top...? Old school.
R

croitoru 20-01-2019 02:59 PM

http://www.ausjeepoffroad.com/forum/...3fffc3218b.png

My #1 definitely all over the place.
R


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