CARWOOD speaks to PART INFO about fault identifications and preventions affecting common rail injectors.
As an approved diesel remanufacturer for leading OE diesel systems from Bosch, Denso, VDO and Delphi, Carwood has immense expertise in fault identification, cause, effect and prevention for various diesel components.
Common rail injectors constantly perform in high-pressure conditions to ensure efficient fuel combustion at every operating point. Pressures can be up to around 2,500 bar/35,000 psi! As a result, the importance of observing best practice and cleanliness from the remanufacturing process to installation is essential. Carwood common rail pumps and injectors are built in a clean-room facility (ISO 14644-1 Class 7).
Due to the very fine tolerances and the multiple sequences involved with the injectors in the common rail system, they can be prone to wear and are typically a high failing part.
Installed in each engine cylinder and connected to the rail via a short, high-pressure pipe, the injector is controlled by the Electronic Control Unit (ECU). This ensures that the nozzle needle is open or closed in microseconds to enable pre-, main and secondary injection – some modern systems can inject up to seven times per engine revolution.
It is important to ensure the cleanliness in the working environment is maintained as contamination from technician’s working practice can lead to problems for injectors. This is especially true for injectors due to their valve size, contamination particles as small as 0.3 to 0.4 microns can cause failure.
Correct fuel grade and filters also play a crucial role to the lifespan of an injector because inadequate filtration and abrasive fuel can causethe injector to break down. Carwood advises to use OE fuel filters and ensure that the correct fuel grade (EN590) is used. With that, service intervals need to be maintained to ensure that the service life of fuel filters have not been exceeded.
When fitting remanufactured parts, OEM-approved products are the most reliable as measures have been taken to ensure that they adhere to the exacting manufacturer tolerances to withstand the high pressures that the system performs in.
EXACTING REMANUFACTURING QUALITY
All remanufactured parts within the common rail range by Carwood use only OE quality component parts and adhere to OE repair processes.
Injector highlights include:
· DFIA2C59511610 Common rail injector for Ford Mondeo 1.8 TDCi (2007-2012)
· DFIA2C59511611 Common rail injector for Ford Tourneo Connect 1.8 TDCi (2009-2013)
· DFI0445110183 Common rail injector for Vauxhall Combo 1.3 CDTi (2009-2012)
Common rail parts supplied by Carwood are tested in accordance to the OE test plan data on OE recommended test benches to ensure that all units meet the specifications and correct coding is applied where needed. Carwood also offer product support with a dedicated technical helpline on 0844 576 2524.