DIY common rail diesel injector repair

Everyone knows that diesel engines are slightly different from gasoline engines in that they have different ignition systems. Therefore, diesel engines do not have a carburetor or an injector; in a diesel engine, in any case, injectors are used to inject fuel into the cylinders. In fact, initially the engine, which ran on diesel fuel, was very dirty, it emitted a lot of harmful gases into the atmosphere, and was also very loud in operation. But such an engine was also very powerful, so it was decided to develop it.

Thus, today diesel engines are already installed not only on trucks, but also on cars, and they are also supplemented with turbines, which give such a motor power. To supply fuel to the combustion chambers, injectors are used, the most popular of which are Common Rail injectors. Therefore, a frequent request in all search engines in this regard is a request for the repair of Common Rail diesel injectors.

Of course, in order not to repair and maintain Common Rail injectors, you need to take care of them. In fact, caring for Common Rail injectors is no different from caring for nozzles of any other company.

You can extend the life of your sprayer by using only quality fuel.

• Therefore, refuel the car only at proven gas stations and only in proven dispensers. Unfortunately, at the same filling station in different dispensers there can be high-quality and low-quality fuel. It all depends not only on what is in the bunker, which is under the refueling, but also on the state of the dispenser itself.
• The second condition that will help extend the life of the sprayer is to change all filters in the car in a timely manner. This must be done because the condition of the spray nozzles directly depends on the condition of the filters. If the filters let through all the debris in the air or fuel, they will instantly clog the jets and have to be cleaned. You can find out how often the filters need to be replaced by reading the instructions for each filter upon purchase.
• In addition, you also need to flush the nozzles with a frequency of 25-30 thousand kilometers by pouring a special agent into the tank.
• The last thing to do to extend the life of Common Rail nozzles, so as not to make repairs ahead of time, is to pay attention to even the smallest changes in the operation of the fuel system and periodically carry out diagnostics.

As already mentioned, it is possible to extend the service life of Common Rail injectors and not make repairs ahead of schedule if you periodically clean it by adding a special agent to the tank. Such cleaning should be carried out every 25-30 thousand kilometers of distance traveled. If this is not done, then the entire fuel system, including the high-pressure fuel pump, can become unusable.

Many people know that repairing the entire fuel system is very important, because without a working fuel system, a car will not be able to drive. You can do this cleaning of Common Rail injectors with your own hands. The second cleaning step does not require removing them from the machine. In this case, the common rail injectors are cleaned due to the fact that air is blown into them under pressure, which is able to clean the clogged nozzles.

There are such blockages when even the second option does not help, in this case the last stage of cleaning the nozzles will come to the rescue.The cleaning process in the third version is based on the fact that the device is immersed in a special chamber, where, under the influence of ultrasound, all particles that clog the jets are destroyed. The only drawback of this cleaning option is that in this case it will be necessary to remove them from the car and take them to a service station, where they are engaged in such work.

Do not think that you will be able to clean completely clogged nozzles with your own hands. Self-cleaning can completely damage the sprayer, passages, or device body. In this case, a complete replacement of nozzles or even nozzles will be required, which will have a negative impact on the driver's wallet.

Our advice: if you do not have experience in this area, it is not recommended to repair injectors with your own hands.

Today there are two types of Common Rail injectors. The first type is electromagnetic, and the second is piezoelectric. The main difference here is considered only the drive of the needle, which, under pressure, releases fuel into the combustion chamber, where it mixes with the fuel.

Besides that there are two types, Common Rail injectors come from different manufacturers. The main manufacturer is considered to be Bosch. This company received such a calling because it produces both types of this device and has been doing it for many years. Other manufacturers (such as: Delphi or Denso) are engaged in the production of only piezoelectric atomizers and produce them in smaller quantities.

As you know, the quality and service life of the device depends on the manufacturer. The firm, which is considered the main manufacturer, occupies this position not only for the reasons presented above, but also because these atomizers will last longer. The company achieved this result by simplifying the design. In addition to being durable, Bosch sprayers are also easy to repair. At the same time, other manufacturers tried to improve their devices by increasing the complexity of the design. The result is a device that is practically unpretentious in terms of fuel quality, but has a shorter service life, but at the same time they practically cannot be repaired in the event of a breakdown. Each driver has the right to independently choose the brand that he trusts more for objective reasons.

When choosing a nozzle, one must proceed from the information that has already been personally confirmed, namely, which nozzles can be repaired and which cannot. There are a number of factors on the basis of which the final choice can be made. One of these factors is the brand of the engine. This must be taken into account for the reason that the manufacturer expects that he will work only with those devices that are installed by the factory, and not with those that will be installed after repair.

There are a number of faults that occur frequently. The main breakdown of all injectors is considered to be a malfunction of the needle, which, under pressure, injects fuel into the combustion chamber, where it mixes with air and burns. But this malfunction may not appear until the car has driven about 180-200 thousand kilometers. Of course, this figure depends not only on the manufacturer, but also on the operating conditions of the vehicle. The instructions for each device in the car describe in detail what conditions the manufacturer expected during manufacture.

If the driver, without reading the instructions, began to use the car or part for other purposes, then it will become unusable ahead of schedule, and Common Rail injectors also apply to this rule. Many drivers, after a malfunction has been found in the device, turn to a service station, where they try to make repairs free of charge under warranty. Most often, in such situations, the driver is denied due to the fact that the device was not used according to the regulations.

Of course, before becoming unusable, the device hints to the driver that this will happen soon.

The main reason that Common Rail sprayers will soon break down is considered to be difficult to start the engine, increased fuel consumption and unstable operation of the power unit.

• In the early stages, this is not very noticeable, but over time, this malfunction becomes more pronounced.
• The second symptom is black smoke from the exhaust pipe, which means overflow and enrichment of the fuel mixture.
• The next symptom is increased fuel consumption, especially on a cold engine, accompanied by a decrease in power.

Many people know that a car is a large mechanism that includes the operation of several units and mechanisms at once. So, if one of them will not work, or will be, but wrong, then the engine may simply not start. One of these systems is fuel. If you do not take care of it in time, do not make repairs, then the car can break down at any time, even on the road. Therefore, it is very important to carry out timely technical inspection and repair of the main devices of the fuel system.

Although modern diesel engines are becoming more and more complex, the Common Rail system appears to be technically even simpler than the previously used mechanical injection pump systems. Ultimately, the Common Rail system completely replaced competing solutions from the market, for example, with unit injectors.

Various concepts.

Several types of Common Rail systems are used in passenger cars. Simplistically, they can be divided into two types (electromagnetic and piezoelectric) and four manufacturers (Bosch, Continental, Delphi, Denso). Bosch, Delphi and Denso are renowned manufacturers of automotive electronics. Bosch has been developing injection systems at the very beginning of the last century. Delphi bought diesel injection technology from Lucas. The Japanese Denso has gained experience working with Bosch and Magnetti Mareli. Continental acquired Siemens and VDO, becoming the main competitor of German Bosch. The injectors of this company have been marked with the Continental emblem for about a year, previously they bore the Siemens logo.

The most versatile is the market leader Bosch, which produces both types of injectors: electromagnetic and piezoelectric. On a much smaller scale, both types of injectors are produced by Delphi and Denso. Continental (Siemens) is exclusively limited to piezoelectric technology.

Each sandpiper praises its swamp.

In advertising brochures, each manufacturer praises their product as the best solution. As you may have guessed, in practice, many of them often have a number of shortcomings. The simplest design is provided by Bosch electromagnetic injectors. Repair of German injectors is not difficult. Delphi wanted to go further and developed a much more sophisticated control system for its solenoid injectors. As a result, his product turned out to be the most sensitive to fuel quality and, unfortunately, not very durable. Among the electromagnetic injectors, Denso is considered the most reliable, but there are difficulties with the availability of spare parts for repair. The most balanced are the piezoelectric injectors designed by Bosch and Siemens (Continental), and also partly by Denso. The injectors are similar to each other, both technically and in terms of reliability. Only Delphi stands out from this group, whose piezo injectors were reputed to be less hardy throughout the entire time.

Whose injectors can be repaired?

From the point of view of the possibility of repair, turbodiesels with classic Common Rail injection from Bosch are most preferable. Almost all specialized centers can handle the restoration of this type of injectors. But the end result depends on the diligence and honesty of the master. Delphi electromagnetic injectors are also repairable, but require replacement of the tip and injector coding after repair. This increases the cost of repairs, but without coding, the engine will run intermittently.Denso solenoid injectors are among the most durable, but repairs are only possible with spare parts available. But with this, just not all is well.

Delphi and Bosch piezo injectors are considered non-repairable. In the case of Siemens (Continental), injection tips have appeared, allowing you to change the size, which allows you to restore the injector to work. However, this only applies to some models with PSA 2.0 HDI 16V engines. Various modifications of this turbodiesel are used in Ford Mondeo IV, Focus, Galaxy, S-Max and Volvo S40, S60 cars.

What to look for?

The advantages and disadvantages of injectors should be known even at the stage of choosing a car. Considering the risk of injector failure, two models with the same engine should be avoided like fire: Ford Mondeo III 2.0 TDCi and Jaguar X-Type 2.0 d. The injectors of the Mercedes E250 CDI W212 of the beginning of production also had congenital defects. The rest of the cars with Delphi injectors raises no objections. Some motors allow the use of injectors from different manufacturers. For example, the 1.6 HDi / TDCi engine had four different types of injection systems, with Bosch being the cheapest to maintain. The situation is similar with 2.0 HDi. Siemens (Continental) injectors can be refurbished, but Bosch piezo injectors cannot.

What you need to know about injectors Common Rail.

Bosch electromagnetic injectors.

They are disassembled and relatively easy to repair. The cost of restoring one injector is about $ 100-150 per piece. They can withstand 200,000 km. In Opel's 1.9 CDTi and Fiat's 1.9 JTD, the injectors are capable of surviving up to 500,000 km. The price of a new nozzle is about $ 250-300 per piece.

Alfa Romeo 159 2.0 JTDM, Fiat Punto 1.3 JTD, Kia CEE'D 1.6 CRDi, Mercedes C 220 CDI W202, Opel Vectra C 1.9 CDTI, Renault Laguna II 1.9 DCI, Volvo V70 D5, BMW 320d E46.

Delphi electromagnetic injectors.

Compared to Bosch, Delphi injectors are much more sensitive to fuel quality. They are slightly more expensive to repair - around $ 150-200 apiece - due to the need to code with a new tip. Average service life is 150,000 km. The cost of a new nozzle is about $ 250.

Dacia Logan 1.5 DCI, Ford Focus 1.8 TDCi, Renault Megane II 1.5 DCI Nissan Almera 1.5 DCI, Hyundai Santa Fe 2.2 CRDi, Kia Carnival 2.9 CRDi, Ford Mondeo 2.0 TDCi III.

Denso electromagnetic injectors.

Denso electromagnetic injectors are considered to be of the highest quality. Until recently, there was a shortage of spare parts, but nowadays most of them can be restored. The cost of repairs is about $ 150-250 per unit. The price of a new nozzle is about $ 450.

Mazda 6 2.0 CD, Nissan Pathfinder 2.5 DCI, Opel Corsa 1.7 CDTI, Mitsubishi Pajero 3.2 DI-D II, Toyota Avensis 2.0 D-4D.

Continental piezoelectric injectors (Siemens).

Previously offered under the Siemens name, and now Continental. They are durable, but until recently were considered non-repairable. Spare parts appear today, and some workshops take on repairs. The resource of injectors is more than 200,000 km. The cost of a new nozzle is about $ 350.

Citroen C5 2.0 HDi II, Mercedes C220 CDI W204, Volvo V50 D4, Peugeot 207 1.4 HDi.

Bosch piezoelectric injectors.

They are found in many modern cars and are structurally very similar to Continental injectors. They also have a similar resource - more than 200,000 km. Unfortunately, they are not repairable. New ones cost about $ 300.

Audi A6 3.0 TDI, BMW 320d E90, Nissan Qashqai 2.0 DCI, Skoda Octavia III 2.0 TDI.

Denso piezoelectric injectors.

They are quite reliable, but not collapsible and therefore cannot be repaired. They are used in a small number of cars. Most often they can be found in Lexus and new Toyota models. The cost of a new nozzle is about $ 500.

Lexus IS 2.2D, Toyota RAV-4 IV 2.2 D-4D.

Piezoelectric injectors - Delphi.

The market is limited. Debuted with the Mercedes E250 CDI BlueEFFICIENCY in 2009 and started causing problems immediately. Later the design of the nozzles was changed.

Mercedes E 250 CDI Bluefficiency.

Injection system malfunctions Common Rail.

As a rule, the Common Rail injection system is able to hold out more than 200,000 km without any problems. But it all depends not only on the design, but also on the operating conditions. The least reliable and most sensitive to fuel quality are Delphi injectors. The first problems sometimes appear already at 140,000 km. The most hardy is Denso's products. Piezoelectric injectors from Bosch and Continental (Siemens), as a rule, can withstand more than 200,000 km. Bosch electromagnetic injectors serve the same amount of time.

Typical Symptoms of Injection System Malfunctions Common Rail:

- uneven engine operation;

- increased fuel consumption;

However, common rail malfunctions are not always the result of damaged injectors. The defect could overtake the high pressure pump, fuel pressure regulator and other sensors. In any case, the parameters of the injection system give an almost accurate answer to the question of the condition of the injectors.

What not to do in the garage.

It is possible to "examine" the system using a special diagnostic computer using the pressure parameters and the so-called "injector correction". Another easy way is to determine the amount of overflow. It is also possible to remove the nozzles for inspection or testing at the stand. Unfortunately, in some cases it is impossible to remove the nozzle - it sticks.

How to renovate.

Technical capabilities allow restoring all electromagnetic injectors (Bosch, Delphi, Denso). Limitations may be imposed by the availability of spare parts: valves, tips, coils, housings, etc.). In the case of Bosch, there are no problems. Slightly worse with Delphi components. And for Denso, the original components simply do not exist. There are only a small percentage of unofficial substitutes. The cost of refurbishment depends on the number of replaced elements and the manufacturer of the injectors. For Bosch, the approximate amount will be from $ 50 to $ 150 per piece, and for Delphi and Denso - up to $ 200-250.

Complete restoration of Bosch, Delphi and Denso piezoelectric injectors is not possible. All that is permissible is to remove the nozzle tip, rinse it in an ultrasonic apparatus and check the operation of the nozzle on the bench.

The situation is slightly better with some Continental (Siemens) injectors. Spare parts are available for individual injectors. The restoration cost is about $ 150.

Disassembly and repair of injectors should be carried out only by specialists of specialized services. Dismantling the nozzle itself requires a special tool. In addition, before and after parsing, it is necessary to check the operation of the injector on a special stand.

- checking the nozzle at the stand;

- dismantling and flushing of elements;

- troubleshooting and replacement of necessary parts;

- adjustment and assembly of the nozzle;

- measurement of parameters after assembly;

- assignment of an individual code, taking into account the characteristics of a particular instance (for some injectors).

Only after the regeneration process and the elimination of related malfunctions (for example, sediment in the tank or chips from the pump in the system), the nozzles can be installed back into place. Along the way, the fuel filter and copper washers under the injectors must be replaced.

In pursuit of excellence, you choose the best. AS8 Club - those who have made their choice.

Message POPINS Wed Feb 13, 2013 6:41 am

Message POPINS Wed Feb 13, 2013 8:10 am

After reading and talking with smart people, we got down to work.
Maybe someone will use the principle of work
The report is taken from here: https://my.housecope.com/wp-content/uploads/ext/1427/technics-repa. -cleaning /

Visual video of the operation of Common Rail injectors

Now let's start assembling
If, after assembly, the injectors are not immediately installed in the engine and put into operation, then all parts must be lubricated. Better diesel fuel - their native liquid, if there is no possibility, then at least something, a liquid key, for example. This is to prevent dry parts from rusting inside.

The nozzle is beautifully cleaned and assembled, ready for action. But its exact working condition can be shown by the stand, which I did. Nozzle works like new - stand verdict

As a result, we get a result in monetary terms equal to 4000, or better a new one for 25000

Since nothing lasts forever, some parts of the nozzle may come to an end, for example, the needle may stick in the atomizer and I really don't know how to get it out neatly without damaging it. The valve seat with the ball can wear out, and the multiplier valve can also lose its steam. In this case, it is possible to order spare parts, here are the codes that we can hammer in existential

Scientists involved in the development of modern engines strive to optimize the operation of the internal combustion unit as much as possible. The improvements that are being implemented in diesel engines are aimed primarily at reducing fuel consumption, increasing power and reducing the concentration of harmful substances in exhaust gases.

All of the above requirements can be successfully implemented in practice if the Common Rail system is used for diesel fuel injection.

The name of the fuel injection system "Common Rail" is translated from English as "common rail". This term very accurately characterizes the principle of supplying fuel to the engine injectors. The pressure in the Common Rail fuel system can reach 2,000 atmospheres. To ensure the delivery of fuel to the injectors, a battery is installed in the Common Rail Delphi power system, in which the diesel fuel is under constant high pressure.

Common rail injectors are an electromagnetic needle valve opening device. The electronic system allows you to accurately set the moment of fuel injection, which makes the engine work as efficiently as possible.