Removing diesel engine injectors
What is a nozzle?
(the second name is “injector”) is a structural element of the engine injection system. Such a device is designed to supply fuel in a measured amount, then spray it into the intake manifold (combustion chamber), i.e. creating a fuel-air mixture.Equipment of this kind is used in all engine injection systems - both gasoline and diesel. Today, modern engines use injectors that are equipped with electronic injection control. Depending on one or another injection method, the following types of injectors are distinguished: electromagnetic, piezoelectric and electrohydraulic.
Having trouble removing a fuel injector from a diesel engine?
Diesel engine injectors, as elements of the fuel system, must function correctly. Failures of these parts disrupt the general scheme by which the diesel engine operates. Many modern diesel engines equipped with a common rail fuel system have a number of serious problems, which we discussed below.
This is mainly due to problems caused by the accumulation of exhaust gases or the result of moisture entering, leading to damage to the cylinder head. Also, on these engines, as a result of the burning of copper washers under the influence of combustion products, the nozzles are practically welded to the cylinder head. With further operation of the car, the situation is aggravated by the fact that the injector body begins to stick to the cylinder head.
In this case, it is impossible to remove diesel injectors yourself without damaging the mounting threads and the injector itself. We do not recommend removing the injector yourself, as this may lead not only to the removal of the cylinder head, but also to the purchase of a new cylinder head. You can see the consequences of removing diesel injectors yourself in the photo.
Trying to remove a diesel injector yourself
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Self-removal of a diesel injector. The injector mounting thread is broken. Further removal of the diesel injector is only possible using special tools. |
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Unsuccessful attempt to remove a soured diesel injector from the cylinder head. |
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The diesel injector mounting thread is jammed. |
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They tried to drill it, but the attempt was unsuccessful. The nozzle remained in place. |
Problems when trying to remove a soured diesel injector yourself:
The threads on the injectors are damaged or torn off;
The nozzle body burst;
Souring of the nozzle in the well due to atmospheric moisture entering the well;
Coking of the nozzle due to gas breakthrough and carbon formation in the well;
The sprayer body remains in the cylinder head, etc.
How to remove a diesel injector?
We provide fast and high-quality delivery of Mercedes, Opel, Renault, Nissan and many other cars. For many services, a serious problem is removing the 4th and 5th injectors of SSang Yong Cayron, Rexton, Action, but we dismantle them even without the need to remove the cylinder head and hood.
Removal of diesel injectors is carried out using a special tool that allows you to remove the injector under any operating conditions.
Removed stuck injectors
Having extensive experience, we will remove them efficiently and with less losses. In our work we use special hydraulic and thread-cutting tools from European manufacturers.
A complete list of cars and engines on which we remove diesel injectors.
In Russia, as well as in other countries of the former CIS, there are a huge number of gas stations. But not every one of them sells high-quality fuel that meets all norms and standards. Most often, gasoline contains not only dirt, but also various impurities and substances. These are phenols, sulfur, various lead acids. In addition, low-quality fuel has a low octane number. Every owner of an injection car should know how to remove injectors. This is useful knowledge that can come in handy when owning a used car.
Symptoms of clogged injectors
As the vehicle is used, the injectors tend to become clogged. On cars with a mileage of 200 thousand or more, they may fail. Often the cause of injector failure is exposure to high temperatures. The inside of this element is covered with varnish deposits. As a result, problems appear during the startup process; it is unstable in all modes.
Due to these deposits and contaminants, the ability to pass fuel is greatly impaired. Problems arise during the process of opening and closing the injectors. All this leads to one or more of these symptoms.
Where are they located?
The injectors on an injection internal combustion engine are located in the fuel rail. Their number is equal to the number of cylinders in the engine.
When to check your work
The injectors responsible for supplying fuel can be used for quite a long time - manufacturers indicate at least 100-150 thousand kilometers. But, given the quality of the fuel and untimely replacement of fuel filters, the need to check and clean them may occur after 80 thousand kilometers.
The need for dismantling most often appears closer to 100 thousand kilometers. The injectors are calibrated, tested, and, if necessary, replaced and cleaned. Sometimes the cause of unstable engine operation may be just one element. There is no need to remove all parts. This is especially true for diesel engines, where the operating process is much more complex compared to its gasoline counterpart.
Removing injectors for diagnostics
Let's see how to remove the injectors to test them. For dismantling you will need a standard set of screwdrivers, wrenches, pliers, injector or carburetor cleaner, and rags.
Let's consider the removal process using VAZ engines as an example. So, the first thing you need to do is lower the pressure that forms in the fuel system. Most modern cars have a special pressure regulator - it is located on This is nothing more than a special valve that you can press. As a result, fuel from the ramp will flow out, and the pressure level will begin to drop.
Gasoline is supplied to the injector at a fairly high pressure, so precautions must be taken when working with them. A jet of gasoline or diesel fuel can cause significant harm.
When you have managed to relieve the pressure, you need to remove the fuel rail. To do this, disconnect the connectors with wires. They can be removed using special clamps, which are an elastic bracket that must be pressed. Next, use a screwdriver to move the clamp along the ramp. After this you can remove the injectors.
Many car owners who do not know how to remove injectors try to pull them out. But this is not how you need to extract them. Dismantling is carried out after slight turns or rocking. Next, use a screwdriver to remove the O-rings - they are located on the injector nozzle on its body. It is worth remembering that these rings can only be used once - if they are removed once, they must be replaced.
Removing diesel elements
Also susceptible to failure due to fuel quality. The dismantling process in this case is different. The main feature is that this element is screwed into the engine, like a spark plug. Operating the injector under high temperature conditions leads to the part sticking to the engine cylinder head.
The nozzle sticks due to moisture entering the well (where the element is installed). Next, the well becomes coked due to exhaust gases breaking through there. Carbon deposits also actively accumulate on the O-rings. The process of removing a fuel injector from a diesel engine, unlike a gasoline engine, requires the presence of additional special tools and pullers. Using pullers, you can reduce the risk of damage to threads and destruction of body parts.
Once the thread has soured, it is very difficult to unscrew the part. During the dismantling process, the nozzle body may simply burst. In this case, you will only have to drill out the part remaining in the cylinder head, then perform other manipulations. For those who do not know how to remove injectors, a rebuild may be required. It must be remembered that an injector is an expensive part. You should carefully unscrew the part from its seat - this is the entire dismantling process.
Examination
There are many ways to check an injector. These are homemade methods, as well as testing methods using special equipment. If you check it yourself, you can only evaluate the opening/closing of the injector. You can also make sure that the injector is not leaking or overfilling fuel. You can also evaluate the quality of the spray during self-testing. Not many people know how to check a removed injector, but all you need to do is connect the power and pass fuel or a cleaning agent through it.
As for diagnostics using professional stands, this equipment allows you to determine more parameters. This is the accuracy of operation, as well as the efficiency of operation of all injectors and each individually. This allows you to accurately and objectively evaluate the performance of the injection system.
Cleaning
We know how to remove injectors from an engine. You should also find out how the process of washing and cleaning them is carried out. You can wash them in two ways - with removal and without removal. A greater effect can only be achieved by washing and removing.
The most common method involves the presence of keys for dismantling, a charged battery, two wires and terminals for them, as well as a cleaning fluid. The fuel rail is removed, and then the injector. The wires are connected to the latter. A can of cleaner is connected to the nozzle through the inlet. Then they press on the sprayer and close the wire to the battery, thereby activating the solenoid valve. You can also assemble a stand for cleaning injectors. But it is very long and expensive.
without removing
For this you need a flushing cylinder. It is made independently. You will also need a compressor and a pressure gauge, a hose that will be connected to the fuel rail. The cylinder is poured into the flushing cylinder and connected to the system. Next, start the engine and turn on the compressor. Cleaning will be completed when all the liquid has been used up.
Here's how to clean the injectors without removing them. The disadvantage of this technique is that there is no way to control the level of contamination, as well as the degree of purification. But this operation requires the least time and effort.
How to remove injectors?
Keeping a personal car in perfect condition is the desire of every driver. Moreover, there is often a need to fix some problems yourself, without the help of specialist auto mechanics. The most common problem associated with the fuel system is contamination of the filter and injector needle with combustion products. As a result, negative processes begin in the engine associated with increased fuel consumption.
Instructions for removing injectors
- Before removing the injectors, it is worth familiarizing yourself with the basic rules of this process. Make sure you have a pair of convenient screwdrivers on hand (a long and a short one is best). They will help remove the fasteners from the part.
- If these nozzles are still suitable for further use, you should use pliers or tweezers when unscrewing. We disconnect the idle air regulators from each of the pipes.
- The removed connector can be cleaned immediately so as not to have to return to this later. Do not forget to also disconnect the crankcase ventilation suction, otherwise it may interfere with your further work. Then you need to disconnect the black strip, which is located just above the injectors.
- Be careful - this tire is secured with clamps, as it serves to control the injectors. Now start disassembling the fuel rail.
- Don't worry if it leaks gasoline - you're on the right track. But safety rules here must be followed more carefully; do not forget that you are working near flammable and explosive substances.
- After removing all the parts, you can begin to directly dismantle the injectors. In this case, it may be necessary to apply some physical force to remove them from the engine. At the same time, it is important not to lose the rubber seal rings - important parts of the injectors, which are on both sides of the part.
A more clear picture of the above instructions can be found on many specialized sites. A video on how to remove injectors will help you understand in detail how to perform this work correctly, and user comments may lead to solutions to other related problems.
Injection nozzles are an integral part of a gasoline or diesel engine. This device is responsible for high-precision dosed injection of fuel under a certain pressure into the intake manifold or directly into the combustion chamber, which depends on the design features and implementation of the power supply circuit of the power unit.
During operation of any type, injector nozzles tend to become clogged. On cars with high mileage, this device may fail, since these elements operate at high temperatures, and often the fuel itself contains many impurities. As a result, the inside of the nozzle becomes covered with varnish deposits.
For the reasons stated above, the throughput is disrupted, problems may occur with both opening and closing nozzles, etc. Under such conditions, the engine loses power, fuel consumption increases, cold starting becomes more difficult, and smoke is observed. With that said, there is a periodic need for replacement as well. Next, we will look at how to remove the injectors yourself, and we will also talk about how to check a removed injector.
Read in this article
When to check injectors and fuel injection quality
Fuel injectors are initially designed for a fairly long service life (100-150 thousand km). At the same time, low quality fuel and untimely replacement of fuel filters can lead to the need for cleaning after 30-40 thousand km. Let us add that there are methods for checking and cleaning injectors that allow you to carry out this procedure without removing them.
The urgent need to remove injection elements often arises closer to 100 thousand kilometers traveled, since by this time the devices usually need not only cleaning, but also detailed testing, injector calibration, or even replacement. The main reasons for such a procedure can be considered increased, noticeably increased fuel consumption, unstable engine operation in different modes (both under load and in transition).
In some cases, it is enough to identify only one faulty element, which allows you to get rid of the fault without having to remove all the injectors from the engine at once. This is especially true for diesel internal combustion engines, where dismantling can be somewhat complicated compared to gasoline-powered analogues. In short, each injector is simply turned off one at a time. The moment when one of the injectors is turned off and the engine smoke stops at the same time will indicate the need to remove and check a specific device without the need to remove the others.
Removing injectors from the engine for diagnostics
On modern injection systems, the element is an electromagnetic device that opens on command to allow some of the fuel to pass through. On most cars, the injectors are installed on the fuel rail (rail). The removal process may differ slightly depending on the type and design of the internal combustion engine, and different tools may also be needed. Often, to remove fuel injectors, you need to prepare:
- Screwdriver Set;
- several keys;
- pliers or pliers;
- carburetor cleaner;
- rags or suitable rags;
Now let's take a closer look at the process and answer the question of how to remove injectors on a VAZ or any other fuel-injected car. First you need to reduce the pressure in the fuel system. Many car models have a pressure regulator on the fuel rail. This regulator is a valve that needs to be pressed. As a result, fuel will flow out of the ramp and the pressure will drop.
Remember, injectors deliver fuel under high pressure. For this reason, care should be taken when working with components that are connected to the engine power system or are tested under pressure fuel conditions. The fact is that a jet of fuel can cause serious injury.
Next, you need to remove the fuel rail on which the injectors are attached. To dismantle it is necessary to disconnect the connectors with wires that are secured using a special clamp. The specified latch is a spring clip that must be pressed. Then you will need to use a screwdriver to move the clamp along the ramp. The injectors can now be removed.
Removal is carried out by slightly turning or rocking the device, after which you need to remove the O-rings with a flat screwdriver. The rings are usually located on the body and on the atomizer. Note that after removal, the rubber O-rings of the injectors must be replaced.
Removing injectors on diesel and direct injection engines
As for the need to remove diesel injectors or similar devices on engines with direct injection, in this case the procedure is slightly different. The main difficulty is that the elements for supplying fuel are “screwed” into the engine like spark plugs. Working under conditions of high heat often leads to injectors sticking to.
The device turns sour because moisture gets into the injector well, coking of the well occurs after exhaust gases break through, carbon deposits accumulate on the sealing ring, etc. The process of removing an injector on a diesel engine with a Common Rail system, as well as units with direct fuel injection, requires the additional presence of special pullers (reverse hammer) and other tools.
The presence of tools and certain skills allows you to avoid frequent problems when trying to remove injectors on internal combustion engines with direct injection: damage to the injector thread, destruction of the device body, finding a part of the nozzle body in the cylinder head after the device is broken, etc.
In other words, the threads become sour and the housing may simply burst during dismantling. As a result, you have to drill out the remaining parts, restore the threads and perform a number of other manipulations. In some cases, after unprofessional removal, partial repair of the cylinder head may be necessary. It should also be remembered that the injectors themselves are expensive devices. Replacing a broken element will result in additional financial costs.
How to check fuel injectors
There are many ways to check fuel injection devices, ranging from homemade ones to testing on special diagnostic stands. When checking independently, it is often possible to assess only the ability of the device to open and close, make sure that the injectors are not “pouring” or overfilling fuel, and also visually assess the quality of the fuel atomization (torch). To do this, power is supplied to the removed injector, and fuel or cleaner is pumped through it.
Let us add that diagnostics using professional equipment allows you to determine the accuracy of operation and the operating efficiency of each element by comparison with the others. This approach provides a much more objective assessment of serviceability and performance, since the operation of injection devices when tested on a bench imitates the operation of these elements on the engine in various modes.
Read also
Signs of malfunction and checking injection nozzles without dismantling. Diagnostics of injector power supply, performance analysis. Tips and tricks.
Removing and installing a pump injector
Sequence of removal and installation of pump injectors in a diesel engine.
1-Radiator frame with attached parts, 2-Bolt (4 pcs. Tightening torque 8Nm), 3-Bolt (2 pcs. Tightening torque 20Nm), 4-Bolt (8 pcs. Tightening torque 20Nm),
Remove and set aside the coolant expansion tank
-Remove the filler pipe of the windshield washer and headlight cleaner reservoir
-Unscrew screws 4
-Screw the guide rods into the right and left side members (2 pieces each)
-Unscrew screws 2 and 3 (left and right)
-Disconnect the intercooler pressure hoses
-Using the guide rods tool, move the radiator frame forward approximately 15 cm in the direction of the arrow.
-Tighten the hoses and wires next.
If there are no guide rods, the radiator frame can be carefully placed on the pads by adjusting their height. The photo shows the approximate position of the radiator frame installed on the pads.
Removing the injector:
-Remove the input manifold
-Remove the casing and the cylinder head cover
-Turn the crankshaft using a wrench so that the pair of cams, respectively, to be installed or removed, point evenly upward. If you do not have a wrench to turn the crankshaft, you can do it differently. Jack up the front wheel of the car. Engage the highest gear. Slowly rotate the wheel with your hands until the cams are in the desired position.
-Loosen the locknuts of the adjusting bolts -1- and unscrew the bolts until the corresponding rocker arm rests on the pump injector pusher spring
-Unscrew the mounting bolts -2- of the rocker arm axle from the outer part inwards and remove the rocker arm axle
-Unscrew the mounting bolt -3- of the pad and remove the pad
-Lift the pump injector connector with a screwdriver. To avoid distortion, support the connector on the reverse side with light finger pressure.
-Insert the puller instead of the clamping block into the side cutout of the pump injector
If you don’t have a puller, you can make one yourself. For example, as shown in the photo.
-Using careful tapping movements, remove the unit injector upwards from its seat in the cylinder head.
Installation of pump injector
1-20 Nm + tighten by 1/4 turn (90°), 2- lock nut, 3- adjusting bolt (replace at each disassembly), 4- rocker arm axle with rocker arm, 5- block, 6- 12 Nm + tighten by 3 /4 turns (270°), 7- pump nozzle, 8- sealing rings, 9- thermal insulation, 10- retaining ring.
When installing a new pump injector on an engine, it is imperative to replace the corresponding adjusting bolt in the rocker arm. New injectors come complete with O-rings and heat seal installed. If an old injector pump is installed, it must be replaced with new O-rings and a thermal insulator. Make sure that the rings are not twisted.
— Lubricate the rings with oil and very carefully install the injectors into place in the engine cylinder head
— Insert the pump injector into the seat by pressing evenly until it stops
— Insert the clamping block into the side cutout of the pump injector
Attention!
If the unit injector is not at right angles to the retainer, the mounting screw may become loose over time, causing permanent damage to the unit injector and seat.
— Screw the new mounting bolt into the block so that you can slightly turn the pump injector
— Install the template as shown between the bearing seat and the unit injector
— Rotate the unit injector body by hand relative to the template
Helpful advice!
If you do not have a template, then before removing the nozzle, measure the gap between the nozzle and the bearing seat (by selecting a plate of a certain thickness). In the figure, the arrow indicates the location of the gap measurement.
— Correct, if necessary, the position of the injector and tighten the fastening bolts. Tightening torque 12 Nm followed by additional turning by 270° (3/4 turn)
— Reinstall the rocker shaft and carefully tighten the new bolts
— Tighten the inner bolts first, then both outer bolts. After this, tighten in the same sequence with a torque of 20 Nm + additional turning by 90° (1/4 turn)
— Install an indicator on the nozzle adjusting screw as shown in the figure
— Rotate the crankshaft in the direction of engine rotation so that the rocker arm roller stops at the top of the drive cam. The roller side (arrow A in the figure) is at the highest point, the indicator (arrow B in the figure) is at the lowest point
— After this you need to remove the indicator
— Then unscrew the adjusting screw from the stop back 180°
— Holding the screw in this position, tighten the locknut to a torque of 30 Nm
— Insert the pump-injector connector into place and secure the engine cylinder head cover.
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