[C38] bad injector on Universal 5424

[Charles Finn]

Jonathan,
I would certainly look at your exhaust, but your comments regarding the 
smoke and fuel coming from the injector suggest you know the problem.  I 
am with Tom (as usual) regarding Nigel Calder's comments...  Due to 
problems with fuel contamination, the injectors are usually not too 
difficult to remove.  Below are the instructions from the Universal 5424 
manual regarding removal (the entire manual is available for download at 
our website).  It is a tight squeeze on the starboard side of the engine 
and the modifications discussed lately regarding port sail locker and 
the inspection port on the starboard, captain's berth will serve you 
well on this.
I think you must remove the offending injector as fuel spraying is a 
definite symptom of a clogged injector.  That suggests the high pressure 
fuel is not able to make it through the injector to the excess bypass 
port that allows excess fuel to flow back to the tank.   And of course, 
that means you are getting lousy combustion on at least one cylinder.  
Injector cleaning is pretty easy, but Tom's comments regarding 
cleanliness are absolutely critical!   If you can get to all of the 
injectors, this might be a good time to have a good look at the (and 
cleaning) to check for cracks and wear.  Most of our engines don't get 
near the hours that would cause wear, but what the heck, they are out 
already! 

Good luck and please let us know what turns up!
Chuck Finn
Mighty Quinn #114
Great Lakes


Basic tools required:
(A) - 10 MM Socket wrench
(B) - 13 MM Socket wrench
(C) - 17 MM Open end wrench
(D) - 12 MM Box end wrench
(E) - 27 MM Socket (1-1/16")

FUEL INJECTORS:
Fuel injectors should be removed and taken to a qualified diesel engine 
repair center to be tested for
leakage and spray pattern, if poor engine performance such as, loss of 
power, rough or uneven running,
sudden notice of dark exhaust, or engine becomes hard to start.
REMOVING INJECTORS:
1. Clean the area around the injectors before removing.
2. Loosen nuts holding fuel lines to injector pump and injector nozzles 
and remove fuel lines
(Tool C).
3. Loosen nuts on return line adaptors and remove adaptors (Tool C).
4. Loosen injectors using (Tool E) and remove injectors.
REPLACING INJECTORS:
1. Check to be sure contact surfaces and area around injectors is clean.
2. Replace injectors in the same cylinder from which they were removed.
3. Torque required to properly seat the injectors will be between 43 and 
58 ft./lbs.
4. Replace fuel return lines and secure nuts.
5. Replace all fuel lines and secure all nuts.
6. After all injectors, fuel lines and hoses have been replaced and are 
secured, the fuel system
will have to be bled. (Refer to bleeding instructions in this manual).
The fuel injection pump has been set at the factory and should need no 
adjustment. Any apparent
problem with the pump should be referred to a qualified diesel mechanic 
or to a Universal Diesel
dealer as advised.

Tom T. wrote:
> Hi Jonathan,
>  
> When I bought my 38  17 yrs ago, I had the same injector problems you 
> describe.
>  
> I removed all three injectors and took each apart, cleaned the parts 
> well and reassembled them.
>  
> When I put them back in the engine, the engine cranked and ran like a 
> new engine and without any noticeable smoke.  You will need to 
> manually prime the injectors by cracking the fuel rail nuts at the 
> injectors or you could destroy your starter waiting for the injectors 
> to prime on their own.
>  
> It's been a very long time since I cleaned my injectors and I no 
> longer remember any details about the procedure but I don't remember 
> anything very difficult about the procedure either.
>  
> I have respect for Nigel Calder so I hate to advise you wrong but I 
> can't imagine what he was alarmed about with working on the injectors 
> if you have basic mechanical skills.  Just keep everything clean 
> because if you leave anything in the injectors, they could clog big 
> time.  This includes lint from your cleaning rag or anything else that 
> could be forced into the injector orifice once the fuel is delivered 
> to the injector.  There is incredible fuel pressure on those injectors 
> and that pressure will force any trash into the injector 
> orifices possibly causing them to clog.
>  
> Good luck,
> Tom Troncalli
>  
>  
>  
>  
>
>     ----- Original Message -----
>     *From:* Jonathan Whitney <mailto:jonwhit23 at aol.com>
>     *To: *listserve at catalina38.org <mailto:listserve at catalina38.org>
>     *Sent:* 3/23/2010 8:44:16 PM
>     *Subject:* [C38] bad injector on Universal 5424
>
>     First, wanted to thank all of you who responded to my last
>     question about heat exchangers (all very helpful - many thanks!) 
>     However, once that got fixed, new issues presented themselves
>     (naturally).  When I turn the engine on, there is lots of grey
>     smoke from exhaust (which has been occuring) AND smoke actually
>     emitting from the center injector (noticeable stream coming
>     directly from the housing holding the injector - this is new).  If
>     the injector were bad/dirty it would certainly explain both
>     problems.  The problem is, I have never removed injectors before
>     and am unsure how to proceed.  Some sources seem to say, just
>     remove them and get them cleaned (or rebuilt if they need to be) -
>     however in Nigel Calder's book, he is adamant about not touching
>     injectors unless its the absolute last resort - and to get a
>     diesel mechanic to address it.  My question is: 
>      
>     -has anyone else had similar problems of smokey injectors?
>     -what would likely cause this to happen?
>     -is this a direct sign of need of replacement or is cleaning possible?
>     -should all 3 injectors be treated equally or is it ok to just
>     remove and clean the noticeably faulty one?
>     -is it time to call a mechanic, or can I safely proceed (without
>     special tools) and not cause damage
>      
>     Any information/help would be greatly appreciated
>      
>     Many many thanks,
>     Jon Whitney
>      
>     Honolulu
>     Hull #54 "Kuu Haku"
>
> ------------------------------------------------------------------------
>
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