Katerina Swanson
Diesel fuel injectors are an essential component of any diesel engine, and their ability to deliver fuel with precision and at high pressure is key to optimising the fuel-air mixture in the engine. Injectors have a huge impact on engine performance and efficiency, and their failure is usually due to the extreme pressure and heat they are exposed to. In this article, we will discuss the process of adapting diesel fuel injectors, including the tools and steps required, and the common issues that may arise.
Diesel Fuel Injectors: Characteristics and Values
| Characteristics | Values |
|---|---|
| Purpose | To convert and deliver fuel into the combustion chamber |
| Function | Direct the spray pattern and angle, influence combustion efficiency, atomize fuel, provide precise control over injection parameters, adapt to varying operating conditions |
| Types | Mechanical, common rail, unit injector systems (HEUI), direct injection, throttle body fuel injection, multi-point fuel injection, sequential fuel injection |
| Impact | Performance, efficiency, emissions |
| Maintenance | Regular oil changes, cleaning, preventing contamination, preventing water in fuel, maintaining good fuel and air management |
| Replacement | Requires a well-trained technician, proper tools, a spotless service area, following manufacturer recommendations |
| Adaptation | PD injectors need to be adapted after installation so the ECU can determine the exact flow rate of each injector |
| Modifying | Enlarging nozzle orifices for increased power, torque, and efficiency; using electro discharge machining (EDM) and extrude honing to smoothen and enlarge nozzle passages |
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What You'll Learn
The history of diesel fuel injectors
Fuel injectors are a relatively new vehicular technology, but the concept is old. Injection systems have been around for over a century, with the first recorded use of fuel injectors in 1902. French aviator Leon Levavasseur implemented a prototype injection system in his Antoinette 8V airplane—the first V8 engine system in history.
In 1872, George Bailey Brayton patented an internal combustion engine with a pneumatic fuel injection system, also known as an air-blast injection system. Rudolf Diesel improved upon this design in 1894, increasing the air blast pressure from 390-490 kPa (57-71 psi) to 6,400 kPa (920 psi). In 1891, the British Herbert-Akroyd oil engine became the first engine to use a pressurised fuel injection system, dispensing fuel oil at high pressure to an injector.
In 1925, Swedish engineer Jonas Hesselman utilised an early form of direct gasoline injection on an early iteration of the Hesselman engine. Two years later, Robert Bosch modified his oil injection pump for use with diesel fuel, introducing the first 'solid' injection system. This became the standard for many years. In 1952, Vernon Roosa patented a rotary pump that was compact and cost-effective, and it began to be used on tractors and higher-speed engines.
In the 1950s, fuel injectors became incredibly popular, and by the 1960s, the M-System was being used in some diesel engines. This system sprayed the fuel onto the walls of the combustion chamber, as opposed to the middle. The 1980s saw the emergence of early digital fuel injection systems, and by the early 1990s, they had replaced carburettors in most new petrol-engined cars in developed countries. The 1990s also saw the introduction of common rail systems on passenger cars, with piezo actuated common rail injectors being introduced by Siemens.
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How to adapt PD injectors
Adapting PD injectors is a complex process that requires careful attention to detail and a good understanding of engine mechanics. Here is a step-by-step guide on how to adapt PD injectors:
Firstly, it is important to work on a cold engine. Use a Torx head screwdriver to remove the cam cover bolts and take off the cam cover. This will expose the cylinder head and the injector rocker assembly, which is our focus. Ensure all injectors are tightened with two screws, torqued to 3.5Nm+90deg+90deg.
Now, place a dial gauge on the cylinder head, adjusting it so that the measuring tip touches the top of the rocker arm adjustment nut. This step can be skipped, but it is the best way to ensure accuracy. Rotate the camshaft with a spanner or by putting the car in first gear and gently rocking it forward.
Next, we will adjust the injectors. Loosen the locking nut (but do not remove it) and turn the Hex key screw clockwise until you feel firm resistance. The injector will now be at its limit stop. Set your angle gauge to zero degrees, and with the relevant Hex key/bit, turn the adjustment screw counter-clockwise by 180 degrees. Hold this position and re-tighten the locking nut with a spanner, then torque to 30Nm with a torque wrench. Repeat this process for all injectors.
Finally, refit the cam cover and ensure that everything is returned to its original position and state. Check that all seals are fitted correctly and that there are no leaks.
It is important to note that some variation in settings may be required depending on the specific injection pump. Always adapt new injectors and ensure that all changes are made mechanically before using the Adaptation for fine corrections.
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Common issues and solutions
Fuel injectors are a vital engine component, designed to convert and deliver fuel into the combustion chamber. They are placed at a specific angle to atomize the fuel and inject it at the optimal point in the combustion cycle, ensuring efficient engine performance.
Exhaust system damage, unusual engine noises, smoke, and power loss
These issues can be caused by a faulty injector, and you may also see a 5-10% decrease in fuel mileage. The most likely cause of premature failure is fuel contamination, which occurs when debris gets past the filtration and destroys sealing surfaces. Water in the fuel is also a common issue.
Solution
Ensure you have a good water separator and regularly check for oil contamination.
Trouble starting the vehicle or uneven idling
The engine cranks but doesn’t start, or it uses different speeds of revs on idle.
Solution
A complete diagnosis is required to find the combustion process element that is lacking, either a lack of fuel injection or a lack of combustion chamber heat.
Misfire
The vehicle misfires on ignition.
Solution
There is a low level of fuel being pumped into the ignition, or the fuel charge in one of the cylinders fails to ignite.
Smell of fuel
The smell of diesel indicates a leak somewhere.
Solution
Have the injectors checked by a professional. A failing fuel injector may allow fuel to flow out when it isn’t active.
Dirty emissions
Modern common rail systems are extremely susceptible to contamination due to the extreme conditions they operate within.
Solution
Ensure a clean service area and tools when replacing injectors to avoid contamination.
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Modifying injectors for performance
Fuel injectors are an essential component of any diesel engine, and their ability to deliver fuel with precision and at high pressure is key to optimising the fuel-air mixture in the engine. This results in more efficient and effective combustion, and thus, better performance.
When it comes to modifying injectors for performance, there are several approaches to consider. Firstly, it is important to understand that simply replacing a functional injector with a larger one will not necessarily make your engine more powerful. Increased fuel flow is important, but it is just one aspect of enhancing engine power. To achieve optimal performance, other modifications may be required in conjunction with injector upgrades.
One common method for modifying injectors is to increase the injector's flow rate by enlarging the nozzle orifices. This can be achieved through a process called extrude honing or abrasive flow machining. This technique involves forcing putty loaded with abrasive material through the existing orifices to smooth and enlarge the passages. As a result, fuel atomisation is improved, leading to enhanced engine performance.
Another approach to modifying injectors is to alter the injector's internal components, such as the plunger and shim, to accommodate larger flow rates. This process requires precise calculations and expertise, as the tolerances are very tight. It is important to note that modifying injectors can be complex, and incorrect modifications can lead to performance issues or even damage to the engine. Therefore, it is recommended to seek professional assistance or consult with experienced individuals before attempting any modifications.
In addition to injector modifications, it is crucial to consider other factors that contribute to engine performance. For example, ensuring the engine is well-maintained and that the oil and fuel systems are properly cared for can help prevent premature injector wear and failure. Moreover, upgrading the air intake system, such as installing a performance air filter or an air intake kit, can increase the oxygen supply to the engine, enhancing combustion and power output. Finally, reprogramming the engine control module (ECU) may be necessary when making performance upgrades to ensure the engine timing adapts to the modifications.
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The future of diesel fuel injectors
Fuel injection technology has come a long way since its inception in the early 20th century, and it continues to evolve and improve. The future of diesel fuel injectors holds many possibilities, with manufacturers pushing the limits of injector design and performance.
One of the key areas of focus for the future of diesel fuel injectors is cleaner burning. Manufacturers are aiming to develop injectors that produce no haze and lower emissions. This is achieved through improved combustion efficiency, where the precise delivery of pressurized fuel into the combustion chamber results in a cleaner and better-performing engine. The goal is to optimize the fuel-air mixture, ensuring that there are minimal unburned particles, which can cause issues such as knocking and higher emissions.
Another area of development is increasing the pressure capabilities of injectors. Injectors that can withstand higher injection pressures are being designed, allowing for more precise fuel delivery and timing. This is especially important in the racing industry, where manufacturers are continuously modifying injector nozzle specifications to accommodate increased flow rates, different spray patterns, and higher injection pressures. The internal components of the injectors must also be modified to maintain precise control over the injection event.
Additionally, there is a trend towards making injectors physically smaller while maintaining or reducing manufacturing costs. This allows for more flexibility in injector placement and design. The number of holes, spray angles, and nozzle designs will continue to evolve, providing even greater control over fuel delivery and engine performance.
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Frequently asked questions
A diesel fuel injector is a vital engine component designed to convert and deliver fuel into the combustion chamber. It plays a crucial role in performance and efficiency.
Before working on a high-pressure diesel system, ensure there is no residual pressure inside the vehicle. Once confirmed, remove the injector pipe, back linkage, electrical connection, and retaining clamp holding the injector. Clean the injector cylinder and remove any fuel, water, or other contaminants. Prepare the new injector in a clean space and install it. Finally, reconnect the high-pressure fuel pipe and confirm your repair by starting the vehicle.
There are two main ways to increase the power: electronically or by physically delivering more fuel. The electronic method involves increasing the fuel flow through the tuners, while the physical method involves installing larger injectors or modifying the injector tips.
Contamination is the leading cause of premature diesel fuel injector failures. Other causes include water in the fuel, clogged fuel filters, failing fuel pumps, and coolant mixing with oil.
