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DIESEL INJECTION SERVICE TIPS

Wear safety glasses when working on a diesel DRIVER

injection system.
ENERGY EFFICIENCY
When in doubt, refer to a service manual for
the make of vehicle being serviced. The TIPS
slightest mistake could upset engine
performance or cause engine damage.

3 Always cap lines or plug fuel end fittings to

prevent entry of foreign matter.
DIESEL ENGINE
4 Never drop a diesel injector or injection pump.
DIAGNOSTICS
They can be damaged.

Remember that high pressure inside a diesel
5.
injection system can cause serious injury.
6 Some diesel injection systems must be bled
(air removed) after repairs.
Most diesel engine problems are related to the
injection s y s t e m . A s s u c h diagnosing diesel
engine problems requires knowledge of engine
and injection system operation

7 Clean around fittings before they are

disconnected.

8 Adhere to all torque specifications. This is

extremely all the more important on a diesel
engine.

9 Never use a bent, frayed, or kinked injection

line. NU
”

10 Place a screen mesh over the air inlet when

the engine is to be operated without the air
cleaner. Rags and other objects can be sucked
into the engine. Also, do not cover the air inlet
with your hand with the engine running or
injury may result. This brochure provides you with the guideline to
troubleshoot various diesel engine and injection
system problems.
11 Check fuel filters and water separators
periodically. Water can cause extensive _
corrosion of injection system parts. -_===_=
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This IS one In a senes of ENEPCON Driver Energy

Efficiency Tips for car owners and auto mechanics
rhrs serves presents basrc rnformatron on techniques
WI ENERCON
for rncreasrng fuel effrcrency in vehicles For further ENERCON Building, G-512, Islamabad, Pakistan
Information contact, Fuel Efficiency In Road Transport
Sector Project, ENERCON Buildrng, G-5/2, lslamabad Tel: + (92-51) 9206005, 9207572
Fax: + (92-51) 9206003
I I
E- Mail: root@enercon.sdnpk.undp.org

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3. ENGINE MISSING 7. FUEL LEAKS
A diesel engine miss results from one or more Leaking fuel lines or loose connections can adversely
cylinders not burning fuel properly This is caused by affect the performance of a diesel engine Pinpointing
injection system problems which include: exact locations of fuel leak become much m o r e easier
when the engine is o n Since fuel is injected at high
. Faulty injectors pressure extra care must be taken as the leaking fuel
. Clogged fuel filters can cause serious injury
. Incorrect Injection timing
. Low engine compression
. injection system leaks
. Air leaks
. Faulty injection pump

4. HARD STARTING
If diesel engine does not start it may be due to-

. In-operative glow plugs

. Restricted air or fuel flow
. Bad fuel flow solenoid
l Contaminated fuel
. Injection pump problem
. Low battery power

A slow cranking speed is a common cause for
starting problem. Being a compression ignition
engine, a diesel engine must crank fast enough to
produce sufficient heat for combustion
3. LACK OF POWER
Lack of engine power may be caused by
. Slack throttle cables
. Incorrect governor settings
. Clogged fuel filters
. Dirty air filters
. Low engine compression
. Other factors affecting combustion
If signs of fuel leakage are detected use a piece of
cardboard to find the leak, move the cardboard
around each fitting. If there is a serious leak, it will
strike the cardboard and not your hand. thereby
avoiding serious injury to your hand
8. CLOGGED FUEL FILTERS
Other than the main filter installed in the fuel line for
draining water, diesels have sock filters fltted In the
fuel tank and some times in the injector assembly as
shown below For optimum performance these filters
must be keot clean

6. POOR FUEL ECONOMY

Poor fuel economy may be due to:

. Fuel leak
. Dirty air filter
. Corrected injection timing
. Leaking injectors
DIESEL TESTS
Diesel Compression Test
Diesel e n g i n e compression t e s t i s similar t o
compression t e s t f o r p e t r o l e n g i n e . I n diesels
compression pressures are in the range of 3.0001
4 500 psi Readings I” each cylinder should be in the
range of 50 to 75 psi of each other
Cylinder-Not-Firing Test
The resistance of each glow plug increases as the
cylinders fire A no change in the resistance of any
particular cylinder’s flow plug will show that the
c y l i n d e r I s N O T firing P y r o m e t e r , a t e m p e r a t u r e
sensing device can be used to detect temperatures at
exhaust of each cylinder to confirm the NOT firing
cylinder
Injection Pressure Test
An injection pressure test uses special valves and
high pressure gauge to test the following,
. Injector opening pressure
. Injector nozzle leakage
. injection line pressure balance
. Injection pump condition
quickly
Due to the verstality of this tester it helps in quickly
locating bad nozzle ed injector filter or faulting
Pump.
DIESEL INJECTOR SERVICE
M o s t diese! engine problems are associated with the
injection system . Major injector system components
have been dlscussed in driver energy tips No 4 titled
“Understanding a n d Maintaining Diesel Vehcles” I n
t h e following s e c t i o n lnformation is provlded on the
proper functional characteristics of the diesel injector
Injector Opening Pressure
Typical diesel Injector opening p r e s s u r e is
approximately 1,700 to 2,000 psi (pound per square
i n c h ) of opening pressure is not wIthin service m a n u a l
specifications, rebuild or replace the injector
Injector Spray Pattern
Some diesel injectors make chattering sound during
operation while others do no:. However. all nozzles
should make a swishing or pinging sound when
spraying fuel
A s shown above there should be a “arrow, cone
shaped mist of fluid. A solid stream of fuel, uneven
spray, excessively wide spray or spray filled with solid
droplets indicates that the injector needs service and /
or replacement
DIESEL ENGINE DIAGNOSTICS

Diesel engine problems that are most f r e q u e n t l y

encountered may be identified as follows

1 Excesive Exhaust Smoke

2. Engine Knocking
3 Engine Missing
4 Hard Starting
5. Lack of Power
6. Poor Fuel Efficiency
7 Fuel Leaks
8 Clogged Fuel Filters

These potential problems are briefly discussed below.
1. EXCESSIVE EXHAUST SMOKE
Excessive diesel s m o k e i s d u e t o i n c o m p l e t e
combustion, n o r m a l l y c a u s e d b y f a u l t y injection
system or other engine troubles A small amount of
exhaust smoke is normal during Initial start-up or
rapid acceleration
White smoke occurs mainly during cold starts. when
the fuel tends to condense into liquid and does not
burn due to cold engine parts. T h e m o s t common
r e a s o n f o r w h i t e smoke are in-operatlve glowplugs
low engine compression, a bad ,n,ector spray pattern
late in~ectlon timing or InJection pump problems
Blue Smoke

Type of Smoke

Abnormal Exhaust smoke may be black, white or

blue. Each type of smoke indicates engine problems
and these are discussed below:
Black Smoke

Excessive blue smoke indicates problems from low

eng,ne compression and/or worn piston r,ngs. scored
cylinder walls or leaking valve stem seals

The blue smoke is caused by crankcase 011 entering

t h e :ombustlon c h a m b e r and b e i n g elnltted a f t e r
partial combustion through the exnaust

2. ENGINE KNOCKING

Excessive black smoke is caused by a rich air-fuel
mixture. T h i s m a y r e s u l t f o r m problems with t h e
lnjection pump or injection timing which may in t u r n
be due to a choked air cleaner, worn fuel injectors,
adulterated diesel fuel or the engine itself
All diesel engines produce a “knocklng” sound when
iunn,ng In a diesel engine fuel lgnltes when Injected
unto the eomoustlon chamber. This rapid combustion
produces very high pressures generating a rumble or
dull clattering sound. Abnormally loud “knocking” may
ae due to mesel engine miss