Diesel Fuel System Service3

Diesel Injection
Diagnosis, Service,
and Repair
© GoodheartWillcox Co., Inc. Permission granted to reproduce for educational use only
Contents
 Diesel injection maintenance
 Diesel injection diagnosis
 Diesel injection service
Diesel Injection
Maintenance
 Refer to manufacturer’s service manual
for periodic maintenance
 Change fuel filters periodically
 Some filters may be drained to bleed off
water
Inlet Connection Screen
Check if problems point to
injection system
Locating Fuel Leakage
Pressure is high enough to make spray
puncture your skin!
Visual Inspection
Check hoses, lines, filters, and linkages
Cleanliness
 Use clean, lintfree shop rags
 Use compressed air to blow dirt from
fittings before disassembly
 Always cap a fitting that is disconnected
Diesel Injection
Diagnosis
 Check for:
 abnormal exhaust smoke
 excessive knock
 engine miss
 “no start” condition
 lack of power
 poor fuel economy
Abnormal Exhaust
Smoke
A small amount during startup, cold
operation, or acceleration is normal
Black Smoke
 Rich airfuel mixture allows carbon (ash)
to blow out of the exhaust system
 Causes:
 injection pump
 timing
 air cleaner
 injectors
 fuel
 engine condition
White Smoke
 Occurs during cold starts
 Condensed fuel particles
 Causes:
 glow plugs
 low compression
 thermostat stuck open
 bad injector spray pattern
 late injection timing
 injection pump
Blue Smoke
 Oil consumption
 Causes:
 worn piston rings
 scored cylinder walls
 leaking valve stem seals
Smoke Meter
Testing device that
measures amount
of smoke in diesel
exhaust
Smoke Meter
 Measures amount of light that can
shine through an exhaust sample
 If the exhaust smoke blocks too much
light, it fails to meet specifications
Excessive Knock
 All diesels produce a knocking sound
 Fuel ignites spontaneously and burns
rapidly
 Ignition lag is the time span between
injection and ignition
 If lag is too long, too much fuel will
ignite at once
Causes of Excessive
Knock
 Low operating temperature
 Early injection timing
 Low compression
 Fuel contamination
 Oil consumption
Engine Miss
 One or more cylinders not firing
 Causes:
 faulty injectors
 clogged fuel filters
 incorrect injection timing
 low compression
 leaks
 faulty injection pump
No Start
 Causes:
 inoperative glow plugs
 restricted air or fuel flow
 bad fuel shutoff solenoid
 contaminated fuel
 faulty injection pump
Lack of Power
 Causes:
 throttle cable adjustment
 governor setting
 fuel filters
 air filter
 compression
Poor Fuel Economy
 Causes:
 fuel leak
 clogged air filter
 incorrect injection timing
 leaking injectors
Scanning Diesel
Problems
 Connect a scan tool to OBD II systems
 Check:
 injection pump solenoids
 electric feed pumps
 fuel tank pressure
 water sensors
Cylinder Balance Test
 Disable one injector at a time
 Loosen injection line to disable injector
 Engine speed should drop and the
engine should idle roughly—if not, the
cylinder is not firing
Cylinder Balance Test
Wear safety
glasses and
leather gloves
Compression Test
 Use a diesel compression gauge with a
600 psi (4134 kPa) range
 Install in the injector or glow plug hole
 Disconnect the fuel shutoff solenoid or
disable the fuel system
 Crank the engine and note the highest
reading on the gauge
 Compare to specifications
 Typically 400500 psi (28003400 kPa)
Glow Plug
ResistanceBalance
 Unplug the wires to all the glow plugs
 Measure the resistance of each glow plug
and record your readings
 Run the engine to operating temperature
 Shut off the engine
 Recheck the glow plug resistances
 If a cylinder is not firing, the resistance of
its glow plug will not increase as much as
the resistance of the other glow plugs
PyrometerBalance Test
 Pyrometer measures temperatures
accurately
 Probe temperature at each exhaust port
 Each reading should be similar
 A cool reading indicates that the
cylinder is not firing
InjectionPressure Test
 Uses special valves and a high
pressure gauge
 Connect the tester between the pump
and the injectors
 Identifies:
 opening pressure
 nozzle leakage
 injection line pressure balance
 pump condition
InjectionPressure Tester
Checks injection
system operation
while the system is
still on engine
Diesel Injection Service
 Injector nozzle service
 Glow plug service
 Injection pump service
Injector Nozzle Service
 A bad injector usually causes the
engine to miss
 reduces engine power and causes
knocking
 nozzles can wear, become clogged, or be
damaged
Injector Substitution
 Easy way to verify an injector problem
 Install a known good injector for one
being tested
 If the cylinder fires, the old injector is
faulty
 If the engine still misses with the new
injector, other problems exist
Injector Removal
 Never remove a component with the
engine running—highpressure fuel is a
hazard!
 Disconnect the battery for safety
 Don’t bend or kink highpressure
injection lines during removal
 Pressfit injectors may require a special
tool for removal
Injector Removal
Note the position of all parts
Impact Puller
May be needed to
remove pressfit
injectors
Injector PopTester
Checks injector
nozzle operation
while the nozzle is
out of the engine
Injector PopTesting
Pump the handle while observing spray
pattern, opening pressure, and leakage
Opening Pressure
 Note pressure reading when the nozzle
opens
 Compare to specifications
 Typical opening pressure: 1700–2200 psi
(12,000–15,000 kPa)
 If opening pressure is not within
specifications, rebuild or replace the
injector
Spray Patterns
Injector Leakage
 Maintain pressure about 300 psi
(2000 kPa) below opening pressure
 At this pressure, the nozzle should not
leak or drip for 10 seconds
Rebuilding Injectors
 Disassemble
 Clean
 Inspect
 Replace bad parts
 injector shims may be used to increase
opening pressure

Rebuilding Injectors
Inspect each part
closely for carbon
buildup, wear, or
damage
Diesel Injector Tool Kit
Contains a soft
brush, gauges, and
other devices for
injector rebuilding
Organizing Tray
Handy when servicing injectors
Installing Injectors
 Coat threads with antiseize compound
 Use a new heat shield or seal
 Screw into head by hand
 Torque to specification
 Reconnect injection line without bending it
 Check for leaks (carefully) after starting
Installing Injectors or
Glow Plugs
Glow Plug Service
 Use a test light to check for voltage to
the glow plugs during cycling
 An inductive ammeter may be used to
check current
 low current may be caused by open glow
plugs or supply circuit
Glow Plug Resistance
Test
Check glow
plug with an
ohmmeter.
Compare
resistance to
specifications
Glow Plug Replacement
 Warning! Glow plugs may be hot!
 Disconnect leads
 Use a deepwell socket for removal
 Coat glow plug threads with antiseize
compound before installation
 Screw into head by hand
 Torque to specification
Injection Pump Service
 Most service is done by specialty shops
with special tools and test stands
 External gasket, seal, and solenoid
repairs may be made in a general shop
Injection Pump
Test Stand
Used to check
injection pump
operation
External
Pump
Repairs
Leaks and faulty
solenoids may be
fixed without pump
teardown
Pump Removal
 Set engine No. 1 piston at TDC
 Observe pump timing marks
 Disconnect battery
 Remove injection lines, linkages, wires,
and fasteners
 Cap all lines
 Remove pump
Pump Removal
Note the parts
that must be
disconnected
before removal
Parts Transfer
This vacuum regulator valve must be
reused on a new or rebuilt pump
Installation
 Align timing marks as you install pump
 Torque fasteners and lines to
specifications
 Reconnect battery
 Air bleeding may be necessary
 The pump will be timed using various
methods
Adjustments
 Injection pump timing
 Cable/linkage adjustment
 Curb idle speed
 Cold idle speed
 Maximum speed
Injection Pump Timing
Rotate the pump
against the direction
of rotation to advance
timing; rotate the
pump with the
direction of rotation to
retard timing
Dial Indicator
A dial indicator may be used to adjust
timing on some vehicles
Luminosity Meter
Technician using a
luminosity meter to
detect combustion
timing for
adjustment
Fuel Pressure Detector
and Scope
Transducer detects
injection pulse
Fuel Pressure Detector
and Scope
Low idle 1700 rpm, injection
occurs sooner
Cable/Linkage
Adjustments
Vacuum Valve
Adjustment
Carburetor angle
gauge may be used
to adjust the
vacuum valve on
this particular
injection pump
External
Adjustments
Curb Idle Speed
 Start engine and run to operating
temperature
 Connect a diesel tachometer
 Adjust to specifications using the curb
idle speed adjusting screw
Diesel Tachometer
Senses crankshaft
damper position
Cold Idle Speed
 Usually performed on a hot engine
 Connect a jumper wire from a battery
feed to fast idle solenoid to raise engine
speed
 Raise engine speed to release solenoid
plunger
 Adjust to specifications, usually by
turning solenoid plunger
Cold Idle Speed
Solenoid
Maximum Speed
 Limits highest attainable engine rpm
 Position tachometer so that it can be
read from driver’s seat
 With the transmission in neutral or park
and the brakes on, slowly press the
accelerator to the floor
 If maximum speed is not within
specifications, turn adjusting screw on
the injection pump
Maximum Speed
Adjustment
Computerized Diesel
Injection Service
 Similar to other computercontrolled
systems
 Use selfdiagnostics and scan tools
 Use digital meters to check wiring,
sensors and actuators

Diesel Fuel System Service3

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Diesel Fuel System Service3

Uploaded by

Copyright:

Available Formats

Diesel Injection

You might also like