Diesel Knock after fitting a replacement injector
 

Hi, this is my first post here. I have had a good look at existing posts - some such as spee are having related issues but nothing quite the same as the knocking under load since fitting an injector that I am getting. I would appreciate any ideas/recommendations..

I have 2003 D5 XC90 105000 miles full volvo dealer servcing. It recently had the drive shaft spline replaced at a local independent volvo specialist as my dealer said they were not familiar with the loss of AWD issue... anyway whilst the car was with the independent he offered to fix poor idle when cold which I had put down to a tired injector but was going to leave until the car was next due for service.

Injector 5 was identified as having a higher fuel return and was replaced with a '36000288 Injector' - £240 inc VAT + fitting. From the forums the number quoted appears to be for a genuine volvo reconditioned item but I was told this was a new item direct from Bosch. I have noted that the independent has used an old plastic cap (with oil and dust on it) so from a visual inspection it is not possible to verify the actual part no. on the car - the cap is a volvo type 2.

Since fitting the car now starts and runs very smoothly and when revving in neutral sounds perfect. However when accelerating there is a knocking noise from 2000rpm upwards that gets louder with load - it sounds to me like pinking. In the 4 years I have had the car it has never made this noise before.

I took it back to the independent and he agreed he could hear the noise but having not heard the car before said he had no comparison. He suggested the noise may be piston slap or a build up of carbon on the piston. He was sure it wasnt related to the injector. However I have since tried unplugging the injector cable and at similar light acceleration/2000rpm the noise has gone completely (although there is then only limited power due to the engine mgt stepping in).

I am concerned as I am shortly going to be driving the car to the alps at high speed and load and if it is pre-ignition i dont want to damage a piston or valves... The independent has said he is confident it will be fine but I am not convinced.

Going to ask the independent tomorrow for the exact bosch part used and re- confirm new but i'm not sure what my next step is.. my thought is to take it to volvo but I am concerned that they will want to replace all the injectors and I cant really afford that especially if its not completely necessary...

thanks in advance for any help...

update - recon injector used...
 

contacted the independent specialist today that fitted the injector - he said it is a reconditioned one from Bosch and it was supplied by german and swedish but he didn't give me the part number - reading elsewhere on the forum it seems like a problem with the injector - question is what to do now!!! Anyone else had a better experience with recon injectors than badt? (post from 2007 copied below)

I am thinking that getting my Volvo dealer to fit a new injector may be the next step..



DO NOT RECONDITION THEM!!!!!!!!!!!!!!!!!!!!!!!!!!!!

Do a search on here for reconditioning injectors. IT CAN'T BE DONE!

So many people have had major problems, including myself very recently (last month to be exact), with Bosch and reconditioning them. Once they recon them it will cause major problems with 'diesel knock'. Also known as 'Pinking'.

After paying £580 to Bosch to recon them I got the car back and even though it started fine. It had developed a VERY bad pinking noise when accelerating. Bosch finally admitted to not being able to recon them and gave me my money back. I have spoken to loads of people on here ALL of which had the same problem. What's even more worrying is that Bosch, who origianlly made the injectors, claim you don't need to use a specific injector (1, 2 or 3) and no reprogramming needs to be done - this is total rubbish!!!!

Pleeeeeeeeeeeease do a search on here and you will read all the heart ache that goes on when using recon/repairing injectors.

The above is correct , volvo use 3 different grades the differences between 1 2 and 3 are miniscule in the amount of fuel they pass these numbers are added after the injectors are tested for flow , so all injectors which are dead on the required specification are marked 2 those that flow slightly less fuel within a certain tolerance are marked 1 and those that pass slightly more fuel are marked 3
All 5 injectors must have the same number and the ECU programmed to suit .
Once you tamper with an injector in any way that grading is lost and you get the troubles you have experienced .

Just buy a new graded volvo injector to match your grade its much cheaper and less hassle in the long term .. ohh and dont forget to renew the corresponding injector pipe , i think they come with the volvo injector ..

corect me if i am wrong clan but vida states that you can change 2 different number injectors before they need re programing??. if you paid that price for a recon what are the dealers selling new or recon ones.

are you sure they have fitted a new injector?? the reason i ask it should have all parts numbers stamped. did you see the print out for the injector test showing no 5 faulty and the figure from the other injectors,
mike

Injector replacement
 

thanks for the responses, that makes a lot of sense that the injectors have the same bosch part no. and then the grading after - that allows for the mechanic's insistence that the correct bosch part was used.

Mike, the test was just a bottle test so no print outs, also nothing from the vehicle diagnostics and although I was originally told a new injector was fitted after checking again today I was told that it was not new but replaced with a reconditioned unit. When I quizzed why re-conditioned I was told "but they all are...".

Assuming this is indeed the problem I am surprised a volvo specialist is not on top of these issues.

I will book in to get the injector changed for a new volvo one and update - btw any idea how much I should pay for a new volvo injector?

the injector kit i purchased was from RUFE around the £280 mark that was for injector, and all washers and clamps and the fuel pipe, i had to replace no5 on mine you pay a surcharge of £40 which you get back when the old injector is sent back this was done by me about 3 months ago hence my question are the dealers using recon injectors or new??, on that point i have no pinking noise. the leak back test in MY opinion should be backed up by the injector test which can be done on vida and if you took it to volvo specialist they should have the equipment to do that.it looks like you are going to have to bite the bullett and get new from volvo if as you say you have a trip to the alps.may i suggest that if you are going to do that they do a road test point out the noise before they fit the correct type injector.if that resolves the issue then sort out the issue with the other garage about the other injector.reading other post on the injector issues i was under the impresion that the injector issue for cold start problems was resloved by volvo for 2003 cars onwards
mike

Sorry i dont quite understand the question .. could you expand on it?
The injectors i have seen new from volvo look exactly that ... brand new ..

It is possible to replace one or two injectors with the different number BUT if a full set is replaced (or 3 or more) the injectors must be reprogrammed


quote (All 5 injectors must have the same number and the ECU programmed to suit ).
mike

right thanks ,

All injectors must be the same grade number so that they all deliver the same volume of fuel , if you have different numbers each cylinder will deliver a different volume of fuel so will produce more or less power . Emissions will be haywire too .