Name : Dewa Gede Adnya Putra

NIM : 0715213050

Class : VIB

Servicing Diesel Fuel-Injection Systems

SHOP FACTS

In a diesel fuel-injection system, the hydraulic lines must with stand very high pressure
and must be noncorrosive. If a hydraulic line requires replacement, install a new lines as
recommended by the engine manufacturer. The hydraulic lines supplied as service part are
preformed and of the proper length. Care should be used in installing them to avoid twisting
or bending them out of shape. If the lines to be replaced is under other lines, you may have to
remove the upper lines.

Whenever lines are disconnected, the lines, nozzles, and pump fittings must be capped.
This will prevent dirt from entering the fuel system. Cleanliness is very important when
working on the fuel system. A dirt particle so tiny as be almost invisible can clog an injection
nozzle.

In a diesel engine, the fuel must be clean and free of contaminants. Figure 24-1 shows the
fuel filters on one engine. A fuel filter work like the filter used in engine lubricating systems.
It contains a cartridge of filtering material (special pleated paper or fiber mat) through which
the fuel must pass. The filter traps any particles and keeps them from entering the fuel
system. The filter should be replaced at specified intervals.

Fig. 24-1 Changing the filter element in a diesel-engine fuel filter

SHOP SKILLS

1. Injection nozzles should not be removed unless there is evidence that they require
servicing or replacement. Usual indications of trouble include :
a. One or more cylinders knocking
b. Loss of power
c. Black exhaust smoke
d. Engine overheating
e. Excessive fuel consumption

2. One way to check for a faulty injection nozzle in a multi cylinder engine is to run the
engine at fast idle. Then loosen the connector at each nozzle in turn, one at a time. If
loosening a connector causes the engine speed to drop off, the injection nozzle is
probably working okay. If the engine speed remains the same, then the injection nozzle
probably is not working properly. It could be clogged so that no fuel flows through. Or
the holes could be partly clogged so that the spray is inadequate or does not have the
required pattern (Fig. 24-2)

Fig. 24-2 Nozzle spray patterns

3. A variety of nozzle are used, but all have a check valve. The check valve opens when
spray pressure is applied so that the fuel can flow through. When the pressure drops, the
check valve closes the shut off the fuel flow rapidly and completely.

4. To remove an injection nozzle, first remove the fuel-return-line clamp and return line.
Then remove the nozzle hold-down clamp and spacer or other connector arrangement.
Remove the nozzle. Cap the nozzle inlet line and the top of the nozzle.

5. Some manufacturers recommend a spray test of the detached nozzle. This requires a
special hydraulic pump which has a pressure gauge. You attach the nozzle to the pump
 and then operate the pump. The fuel should spray from the nozzle when the pump
reaches the specified pressure. When the pressure is released, the spray should stop
abruptly without dripping.

6. If the nozzle does not work properly, it can be disassembled and cleaned. Some
manufacturers recommend replacing a defective nozzle. If you disassemble a nozzle,
work carefully to avoid damaging the tip or enlarging the holes.

7. Servicing of the fuel injection pump is a specialized job usually done by a shop that
specializes in fuel-injection work. When the fuel-injection pump requires service, the
technician usually will remove it and install a new or rebuilt pump.

JOB 24 : MULTIPLE-CHOICE TEST

1. Black exhaust smoke may indicate

a. Water in the fuel
b. A defective injection nozzle
c. Oil in the fuel
d. Excessive engine speed

2. One purpose of the nozzle check valve is to

a. Shut off fuel flow rapidly and completely
b. Prevent dirt from entering the nozzle
c. Clean the fuel
d. Allow easy removal of the nozzle

3. If the high-pressure spray from a nozzle hits your skin, the fuel may cause
a. A fire
b. An explosion
c. Dirty hands
d. An infection

4. When disassembling a nozzle, be careful to avoid

a. Scratching the housing
b. Damaging the tip or enlarging the holes
c. Cleaning the holes
d. Removing the lubricant

5. A defective fuel-injection pump normally is serviced by

a. The technician overheating it
b. The part department overhauling it
c. Replacing it with a new or rebuilt pump
d. Disassembly and cleaning