Injector Removal Tool Solves Common Injector Failures

Common Failures

1. Cold Diesel Engine Issues: When the engine is cold, it may face starting difficulties, emit white smoke, and experience high fuel consumption. As the temperature rises, the smoke may turn black. The injector’s needle valve sealing cone undergoes frequent impacts and high-pressure fuel injection, leading to wear or spotting, causing leakage. Check the needle valve's movement for flexibility and wear on the cone surface. Replace parts if necessary.
2. Reduced Injection Pressure: Worn needle valve couplings or poor sealing between the needle valve body and injector shell reduce injection pressure, delay timing, lower engine power, and can even cause stalling. Excessive return fuel due to wear may worsen the issue and affect performance.

Solution Using the Injector Removal Tool

• Since injectors are removable, they must be regularly disassembled for repair or replacement. Use an injector removal tool for easy disassembly. Always release pressure when clamping injectors, and avoid putting hands near the injector during tests.

Injector Disassembly Method

Disassembling the Injector Assembly:

• Loosen the high-pressure oil pipe nut (release pressure).
• Remove the high-pressure oil pipe and clip.
• Remove the oil return pipe.
• Use a spreader bar to remove the injector assembly.
• Prepare parts: 6 plunger couplings, 6 injectors.

Decomposition of the Assembly:

• Fix the injector in a vise, remove the cap with a wrench.
• Spin out the adjusting screw.
• Remove the gasket, spring, and arbor.
• With the nozzle facing up, remove the cap nut with a socket wrench.
• Remove the needle valve coupling.

Assembly:

• Reassemble in reverse order, ensuring:
• The positioning pin aligns with the injector positioning hole.
• Tighten the nozzle cover nut to 42-50 N/m torque.
• Ensure spring elasticity is correct.
• Adjust the screw to the proper depth.