Cummins 2 8 DIY nozzle repair

In detail: Cummins 2 8 DIY nozzle repair from a real master for the site my.housecope.com.

Engines of the cummins series, and in particular the cummins isf 2.8, are currently installed on such cars as Gazelle, Gazelle NEXT, GAZ 2752 Sable and are an excellent diesel engine. The cylinder block is cast from cast iron, the cylinder liners are milled into the block. Thanks to milling, significant block strength and material savings are achieved. When the liner wears out, then during a major overhaul, it can be very simply replaced or it can be sharpened to the first repair size.

The block head is made in one piece, with four valves per cylinder. The valves are driven via rocker arms from the camshaft. The nozzle of the cummins isf 2.8 engine is located clearly in the center of the cylinder... All valves are made of high temperature resistant material and the valve stem is chrome plated to prevent scoring and chipping. If you have to buy the whole set, as the valves are not interchangeable. The crankshaft of the cummins isf 2.8 engine is made of gray cast iron, the pulley with the shaft is one-piece. The camshaft is driven by a chain and is carried out through an intermediate gear. The chain drive of the cummins isf 2.8 engine, although it adds a little noise, is quite tolerable for a truck.

Well, having figured out the minimum device of the cummins isf 2.8 engine, you can go to one of the main questions: how the injector is cleaned. And we are interested in how to do it on our own, for example, on a long journey or when it is often not cost-effective to contact the service. For example, when a GAZelle participates in a small business, and its driver is "handy" enough not to go to the service.

Video (click to play).

The first symptoms in order to start thinking about cleaning the injectors can be the twitching of the car when the accelerator pedal is pressed sharply, dips when picking up speed, and if the air is humid, then the car does not drive at all.

At the service station, the nozzle is cleaned using special equipment - ultrasound. After visiting the service and carrying out cleaning, the efficiency of the power supply system is restored almost completely, that is, the fuel mixture is much better distributed over the cylinders and is sprayed better. We will pay attention to the methods of self-cleaning of the nozzles, we will have two of them. We need these things:

Injector and carburetor cleaning kit.
Special rubber seals.

Cleaning the injectors of the cummins isf 2.8 engine

Now let's start parsing. First, carefully remove the barrel with the idle speed regulator (IAC) pipes, then disconnect the wires from the injectors and remove their clips. Now you need to carefully remove the nozzle bar, everything must be done carefully so as not to break anything. After removing the nozzles from their seats, you need to soak them in some unnecessary container in the liquid for the injector cleaner. While the injector of the cummins isf 2.8 engine is “turning off”, we will prepare the following tools: a foot pump with a pressure gauge and an accumulator. Also, in order not to waste time, you can clean the IAC with a carburetor cleaner. Next, we remove carbon deposits with a needle, we must clean everything around the nozzle. To completely clean the nozzles we have to flush them. To do this, we remove the hose from the pump and fill it with a cleaner, then we connect the hose to the nozzle and apply voltage to it. We repeat with each nozzle, after which we put everything back. The second method is longer, but cheaper. We do everything in the same way, but it will be necessary to pour a carburetor cleaner into the hose from the pump, and we remove the external carbon deposits with a cloth moistened with the same cleaner.The carbon deposits will slowly dissolve. That is why this method is longer. Next, put the nozzles in place in the same way.

The fuel system uses electro-hydraulic injectors, which are controlled by an electronic control module. High pressure fuel is supplied to the injector from the rail.

A solenoid valve located at the top of the injector activates a needle that delivers the required amount of fuel through a nozzle to each cylinder.

Multiple fuel injection is carried out by the command of the electronic module (ECM), which controls the operation of the solenoid valves of the injectors. The gaps in the nozzle nozzle openings are too small and any debris entering them will clog the nozzle. Therefore, it is important to remove dirt around all fittings in the fuel system before servicing.

The high pressure fuel line fitting has a slotted filter that crushes small dirt particles that enter the fuel system. It uses high-frequency fluctuations in fuel pressure to break down most of the particles to a size that matches the flow area of the injector.

All injectors are connected to a common low pressure fuel return line. All excess fuel from the injectors, rail, and fuel pump is returned to the fuel tank through the low pressure fuel line. A low pressure check valve is installed in the low pressure line, which prevents fuel from returning to the injectors along this circuit. The drain lines are provided with push-type fittings with lynch clips on each nozzle.

If the injector is faulty or partially faulty, the engine will run unstable, consume more fuel, and the engine will "shake". Fuel leakage through the drain line, as a result of a malfunction of any injector, can be checked as follows:

Disconnect the fuel drain line from each injector

Press on the latch fixing the drain pipe union

Disconnect the return line from the nozzle

We connect the separate drain hoses included in the nozzle leak test kit (catalog number 4918899). If this kit is not available, suitable sized hoses can be used.

We lower all four hoses into separate measuring containers.

We start the engine and measure the amount of fuel collected per minute. We compare the results for each injector.

The maximum fuel consumption for each injector should be 20 ml / min.

Do not remove the injectors unnecessarily!

Disconnect the negative terminal of the battery

We clean the area where the nozzle is located with compressed air or steam.

Press the latch and disconnect the wiring block from the injector

Press on the lock fastening the drain pipe fitting to the nozzle

Disconnect the pipeline from the nozzle

Unscrew the nut securing the high pressure pipe to the rail

Holding the nozzle fitting from turning, unscrew the nut securing the high pressure pipe to the nozzle

The first GAZelles with Cummins engines appeared on the market in 2010. At the first stage, the appearance of a diesel engine instead of the familiar 406 gasoline engine, the drivers of minibuses took hostility. But today the share of sales of GAZelles with diesel engines is about 80% of the total sales of these popular trucks.

Today we got our hands on fake Bosch injectors for the Cummins ISF 2.8 engine and we invite you to look at their differences from the original products.

Nozzle numbers: 5258744, 0445110376, 0 445 110 376 (old) and 5309291, 0445110594/0 445 110 594 (new)

Original injectors for the ISF2.8 engine are sold in photon, Bosch and Cummins packaging. These nozzles are produced specifically in Japan today, then they go to China and are packed there, so we were immediately confused by the Bosch packaging with the inscription “Made in Germany”.

We open the box and see what's inside.

1. The first thing that immediately fell on our eyes was a different font. On a fake, it is dull and not as clear as on the original.

2. Next, we noticed a significant difference in the thickness of the copper rings. On a fake, they are much thicker.

Differences in the material of the nozzle body are also visible here.

3. Look at the nozzle body again. In the original, it is ribbed, on a fake it is almost smooth, it can be seen even in the photo. The original is engraved with a code.

4. On the counterfeit, the date is engraved indistinctly and not where it was on the original. Differences in the material are also visible.

5. There are differences even in the stubs. There is a code on the original caps, there is nothing like that on the fake.

High-precision injectors ensure high-quality engine performance. Modern nozzles are varied in their types.

Their differences are due to the types of fuel systems that are used in diesel engines. Therefore, in order to understand the design and repair features of the injector, it is necessary to understand the principle of operation of a particular system for supplying fuel.

Regardless of the type, fuel systems perform the same tasks. Any fuel system should create the highest possible pressure during fuel injection.

Due to the high pressure, a portion of the fuel is atomized into small fractions. This promotes its rapid evaporation and mixing with air, and, consequently, improves the quality of the resulting air-fuel mixture.

In order for the fuel system to clearly perform its functions, its design is constantly being improved, electronic control of the injection system is used, and various technologies are used to ensure optimal fuel injection. There are three types of fuel systems used in a diesel internal combustion engine:

classic system using a high-pressure fuel pump (high pressure fuel pump);
a battery-type fuel system with a common fuel line (Common Rail);
system in which pump-nozzles are used (Pumpe-Duse).

Cummins engines use a variety of fuel delivery systems to accommodate different injectors. However, each of them meets international requirements for reliability and environmental friendliness. In addition, Cummins injectors can be repaired, which reduces the cost of operating the engine. Next, we will consider methods for troubleshooting and repairing Kamens injectors.

Poor quality fuel can lead to wear and erosion of injectors. In addition, just like other parts of a car that interact with hydraulic fluids and air, injectors are susceptible to corrosion.

In this case, the most common failure of a nozzle is a failure of the atomizer. In addition, subject to wear: the nozzle nut, the nozzle body and fungus, and the spacer. Wear is manifested in mechanical damage and deformation of the nozzle parts, as well as a change in the linear dimensions of its parts.

There are external signs by which you can determine the need to check the condition of the injectors. These features include gaps and loose fit between the body and other parts of the nozzle, resulting from linear distortions or wear of the atomizer mounting nut.

The oil volume of a Kamens engine depends on the type of engine, the number of cylinders and the type of oil pan. An insufficient amount of oil leads to a decrease in pressure and deterioration in the performance of the lubrication system.

The peculiarity of the assembly of the gas distribution mechanism of the Kamins engine is that during it, parts made of heat-resistant steel are used, and the exhaust valves installed in the engines are made of chrome-silicon alloy. Engine assembly details are here.

Another alarm is a drop in pressure that causes the nebulizer to open. In normal operation, during the entire period of operation of the nozzle, the opening pressure should not decrease by more than 10% from the nominal value set by the manufacturer. Excessive pressure drop can be caused by wear on the spring or on the nozzle surfaces.

A worrying factor is reduced fuel delivery to the atomizer and improper injection. All this affects the quality of the engine's operation and leads to a loss of power or an increase in the opacity of work.

Any internal leakage from a fitting or injector will increase fuel flow through the return line.

Checking the leaks with the cylinders shutting off in turn will not help to determine the location of the leak, since it is located before the needle valve of the injector.

Since all injectors receive fuel from a common fuel line, losses will be distributed evenly across all cylinders.

There are a number of operations, individual for each engine model, focused on separating the fuel streams and measuring the fuel consumption coming from the injectors.

Initial check

After the preparatory operations have been carried out, you can start measuring the level of fuel consumption, but first, remember the important rules.

So, we start checking and first of all we start the engine. Next, enable the Fuel Leak Test available with the INSITE ™ Diagnostic Kit. It is necessary to wait at least a minute for the nozzles to warm up to operating temperature, as this will provide more accurate measurements.

Install the drain hose into a graduated cylinder and measure the amount of fuel flowing out per minute.

Fuel consumption rating with INSITE ™ check enabled

4-cylinder - no more than 200 ml,
6 cylinder - no more than 300 ml

Standard fuel consumption in idle mode

4-cylinder - no more than 120 ml,
6-cylinder - no more than 180 ml.

It should be borne in mind that in this mode, it is possible not to detect a fuel leak.

If fuel consumption is higher than the specified limits, it makes sense to carry out a check with insulation of the injectors.

Having found out that the problem of excessive fuel consumption in the injectors, they should be removed and checked for the possibility of further operation.

Dismantling a nozzle is an operation that requires accuracy and skill. With special care, it is necessary to dismantle when repairing Cummins pump injectors, or repairing Common Rail injectors, since due to the complexity of their design, there is an increased risk of damage.

It should be noted that the removal of the injectors should be resorted to only if the malfunction was confirmed by diagnostic procedures. The injector can only be dismantled with the ignition off after preliminary cleaning of all connections of the fuel system with stiff brushes, rinsing and drying with compressed air.

Training: remove the fuel line, the fuel line fitting, the rocker arm cover and the exhaust rocker itself.

Removing the injectors. First, disconnect the wiring leading to the solenoid valve, and then remove the two bolts of the injector holder, and then the holder itself. Remember, the injector holder is not removable on all engine models. Use a special nozzle puller, or you can use a small pry bar to pry the nozzle by the pressure flange.

Use a cloth soaked in solvent to clean the nozzle body and tip. Check tip for corrosion or carbon deposits. Check all terminals of the solenoid valve for damage.

Check the end of the fuel line fitting and the injector inlet for damage.If overheating took place during the operation of the injectors, then blue or dark yellow spots will appear on it (depending on the overheating temperature).

Check the injector O-rings for damage and replace if necessary.

After a general inspection, repair of the cummins injector pump and, if necessary, replacing defective parts, we proceed to installation.

First of all, make sure that the hole for the nozzle is clean and that there is only one sealing washer on the nozzle itself. The nozzle holder should face the rocker arms with the rounded edge and the nozzle inlet facing the manifold.

Lubricate the O-ring with engine oil and align the injector in the correct position on the cylinder head (inlet facing the fuel line fitting). Check that the nozzle fits snugly in the hole.

If the injector is without the solenoid valve packing cover, try to avoid applying force to its terminals, as they may break if pressure is applied to them when installing the injector.

Maxim76 03 Jul 2013

If the repair shop has good equipment, then after the repair you should be given a new code for the injector.

Does this mean that having bought a used one? the injector, you can get lost, and the internal combustion engine may not work correctly if the injector has already been repaired and there is no post-repair injector code?

I don’t know from anyone how, but I have never seen injectors with the same code.

Even replacing one faulty injector with a new one, with three old working engines, the engine may not work correctly - especially at idle.

Add the code. go through the adaptation procedure and you will be happy within 15-20 minutes

what code, if the old and working one pours 4 cubes at idle, while it fits into the test plan, and the new one gives 2 in the filling and is also in tolerance, I had such cases.

The most common reason for complaints from drivers of GAZelles with a Cummins diesel engine is problems with the fuel equipment, namely, the breakdown of Common Rail injectors. Today, Cummins ISF 2.8 engines are installed on diesel GAZelles.These are very reliable engines that are produced all over the world. However, like any other Cummins ISF 2.8 diesel engine, it is sensitive to any impurities in the fuel. Most dangerous: water and dirt. Not all owners of fixed-route taxis and trucks, after long-term operation of a gasoline engine, have the necessary skills to properly maintain a Common Rail diesel engine. In addition, many individual entrepreneurs who work on route GAZelles and as private freight carriers do not have their own garage to perform maintenance and timely check fuel equipment. This leads to the fact that their nozzles fail much earlier than the estimated date.

change filters and oil at least once every 10,000 kilometers.
use only original filters
use additional water separators.
refuel only at reliable gas stations.

Even these simple habits will help you extend the life of your atomizers for a much longer period.

If your GAZelle suddenly has thick black smoke, or the engine starts to work with a knock, and the idle speed becomes floating and unstable, then there is a high probability that the nozzles of your GAZelle have already suffered. Do not despair, Bosch injectors that are installed on these Cummins engines have excellent maintainability. Our auto center has extensive experience in the repair of GAZelle injectors.

We strongly advise you to contact our service at the first sign of a malfunction in the fuel system and not to operate a car with a faulty injector. It must be remembered that such an injector can spray a larger amount of fuel into the cylinder, which can cause the engine to "run wild". I would also like to warn you against trying to repair GAZelle injectors with your own hands. Quite often, this only leads to the fact that after the repair you have to order new injectors, which are much more expensive than the price we offer to pay for a high-quality repair of injectors.

Please note that if metal shavings are found in the fuel lines, the cost of repairing the GAZelle fuel system with a Cummins 2.8 engine may increase significantly, since this indicates a malfunction of the injection pump, which cannot be repaired. That is why we advise you to repair the injectors at the earliest stage, until their malfunction and dirt in the fuel system cause more serious engine problems.

How to remove a CUMMINS ICE injector in two minutes

Cummins 2.8 remove sour nozzles.

It will focus on methods of cleaning and replacing injectors in series engines. Cummins ISF2.8, which are equipped with cars produced by the domestic manufacturer "GAZ".

The cylinder block is cast, with milled liners, which significantly increases strength. The engine is four-valve, the valves are made of heat-resistant steel, with a chrome-plated stem and are non-interchangeable. The camshaft drives the valves by means of rocker arms. Chain drive with implementation from the crankshaft through an intermediate gear. The crankshaft pulley is one-piece.

As you know at the service station, cleaning is performed using ultrasound, however, an ordinary car owner is unlikely to have such equipment, which we will analyze in such cases. First, you need to diagnose the problem. Signs of contamination of the Gazelle-Business 5258744 ISF 2.8 injector are: loss of engine power, unstable idling, the appearance of detonation. If you find these symptoms, prepare the following tool:

• Injector and carburetor cleaner fluids.

• Rubber sealing rings.

Let's start with the analysis. The first step is to remove the idle speed sensor, then disconnect the power cables and injector clips. The next step is to remove the nozzle bar. Next, you need to take an unnecessary container and soak the nozzles in the liquid for the injector cleaner. It is necessary to let the nozzle "sour", during this time you can clean the idle speed regulator with a carburetor cleaner fluid and prepare a pump with a pressure gauge. Then with a needle you need to clean out the carbon deposits around the nozzle. We start flushing: pour the cleaner into the hose from the pump and, having connected the nozzle, rinse it. We repeat for each nozzle. Checks the Cummins ISF 2.8 fuel pressure sensor

There is also a second method, it will take longer, but it will be cheaper. We perform all the same actions, but pour a carburetor cleaner into the hose from the pump, and remove the external carbon deposits with a piece of rag moistened with the cleaner. We collect again in the same way.

Video (click to play).

The symptomatology of the need to replace the nozzle nozzles is the same as for cleaning, so after disassembling the nozzle, you can immediately decide whether to change the nozzle and the Gazelle fuel pump. So, let's get started: prepare the place, arm ourselves with two containers of diesel fuel and a set of keys, you can use yews or clamps for fixing. First you need to unscrew the union nut on the nozzle body. We tear off slightly, and then unscrew it with our hands. It happens that the spray is stuck to the nut, then you need to carefully knock it out with a rod of a suitable diameter. We put a nut in one container, and in the second we rinse the intermediate body, having previously removed it. After these manipulations, we take a new atomizer and start reassembling. Checking the Cummins ISF 2.8 dosing unit. We take everything out of the trays so that the dirt remains in the fuel. We put the sprayer, tighten the nut, the nozzle is assembled on this. A stand is used for testing, however, in the absence of a pump, you can use the method described above. If the pressure is below normal, we check the nut, if everything is normal, we put it in the car.

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