1. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Publisher The Goodheart-Willcox Co., Inc. Tinley Park, Illinois by Russell Krick

2. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only

3. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Diesel injection maintenance  Diesel injection diagnosis  Diesel injection service

4. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Refer to manufacturer’s service manual for periodic maintenance  Change fuel filters periodically  Some filters may be drained to bleed off water

5. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Inlet Connection Screen Check if problems point to injection system

6. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Locating Fuel Leakage Pressure is high enough to make spray puncture your skin!

7. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Visual Inspection Check hoses, lines, filters, and linkages

8. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Cleanliness  Use clean, lint-free shop rags  Use compressed air to blow dirt from fittings before disassembly  Always cap a fitting that is disconnected

9. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Check for:  abnormal exhaust smoke  excessive knock  engine miss  “no start” condition  lack of power  poor fuel economy

10. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Abnormal Exhaust Smoke A small amount during start-up, cold operation, or acceleration is normal

11. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Black Smoke  Rich air-fuel mixture allows carbon (ash) to blow out of the exhaust system  Causes:  injection pump  timing  air cleaner  injectors  fuel  engine condition

12. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only White Smoke  Occurs during cold starts  Condensed fuel particles  Causes:  glow plugs  low compression  thermostat stuck open  bad injector spray pattern  late injection timing  injection pump

13. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Blue Smoke  Oil consumption  Causes:  worn piston rings  scored cylinder walls  leaking valve stem seals

14. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Smoke Meter Testing device that measures amount of smoke in diesel exhaust

15. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Smoke Meter  Measures amount of light that can shine through an exhaust sample  If the exhaust smoke blocks too much light, it fails to meet specifications

16. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Excessive Knock  All diesels produce a knocking sound  Fuel ignites spontaneously and burns rapidly  Ignition lag is the time span between injection and ignition  If lag is too long, too much fuel will ignite at once

17. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Causes of Excessive Knock  Low operating temperature  Early injection timing  Low compression  Fuel contamination  Oil consumption

18. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Engine Miss  One or more cylinders not firing  Causes:  faulty injectors  clogged fuel filters  incorrect injection timing  low compression  leaks  faulty injection pump

19. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only No Start  Causes:  inoperative glow plugs  restricted air or fuel flow  bad fuel shutoff solenoid  contaminated fuel  faulty injection pump

20. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Lack of Power  Causes:  throttle cable adjustment  governor setting  fuel filters  air filter  compression

21. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Poor Fuel Economy  Causes:  fuel leak  clogged air filter  incorrect injection timing  leaking injectors

22. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Scanning Diesel Problems  Connect a scan tool to OBD II systems  Check:  injection pump solenoids  electric feed pumps  fuel tank pressure  water sensors

23. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Cylinder Balance Test  Disable one injector at a time  Loosen injection line to disable injector  Engine speed should drop and the engine should idle roughly—if not, the cylinder is not firing

24. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Wear safety glasses and leather gloves Cylinder Balance Test

25. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Compression Test  Use a diesel compression gauge with a 600 psi (4134 kPa) range  Install in the injector or glow plug hole  Disconnect the fuel shutoff solenoid or disable the fuel system  Crank the engine and note the highest reading on the gauge  Compare to specifications  Typically 400-500 psi (2800-3400 kPa)

26. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Glow Plug Resistance-Balance  Unplug the wires to all the glow plugs  Measure the resistance of each glow plug and record your readings  Run the engine to operating temperature  Shut off the engine  Recheck the glow plug resistances  If a cylinder is not firing, the resistance of its glow plug will not increase as much as the resistance of the other glow plugs

27. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Pyrometer Balance Test  Pyrometer measures temperatures accurately  Probe temperature at each exhaust port  Each reading should be similar  A cool reading indicates that the cylinder is not firing

28. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injection-Pressure Test  Uses special valves and a high- pressure gauge  Connect the tester between the pump and the injectors  Identifies:  opening pressure  nozzle leakage  injection line pressure balance  pump condition

29. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injection-Pressure Tester Checks injection system operation while the system is still on engine

30. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Injector nozzle service  Glow plug service  Injection pump service

31. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injector Nozzle Service  A bad injector usually causes the engine to miss  reduces engine power and causes knocking  nozzles can wear, become clogged, or be damaged

32. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injector Substitution  Easy way to verify an injector problem  Install a known good injector for one being tested  If the cylinder fires, the old injector is faulty  If the engine still misses with the new injector, other problems exist

33. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injector Removal  Never remove a component with the engine running—high-pressure fuel is a hazard!  Disconnect the battery for safety  Don’t bend or kink high-pressure injection lines during removal  Press-fit injectors may require a special tool for removal

34. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Note the position of all parts Injector Removal

35. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Impact Puller May be needed to remove press-fit injectors

36. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injector Pop Tester Checks injector nozzle operation while the nozzle is out of the engine

37. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injector Pop Testing Pump the handle while observing spray pattern, opening pressure, and leakage

38. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Opening Pressure  Note pressure reading when the nozzle opens  Compare to specifications  Typical opening pressure: 1700–2200 psi (12,000–15,000 kPa)  If opening pressure is not within specifications, rebuild or replace the injector

39. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Spray Patterns

40. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injector Leakage  Maintain pressure about 300 psi (2000 kPa) below opening pressure  At this pressure, the nozzle should not leak or drip for 10 seconds

41. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Rebuilding Injectors  Disassemble  Clean  Inspect  Replace bad parts  injector shims may be used to increase opening pressure

42. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Rebuilding Injectors Inspect each part closely for carbon buildup, wear, or damage

43. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Diesel Injector Tool Kit Contains a soft brush, gauges, and other devices for injector rebuilding

44. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Organizing Tray Handy when servicing injectors

45. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Installing Injectors  Coat threads with antiseize compound  Use a new heat shield or seal  Screw into head by hand  Torque to specification  Reconnect injection line without bending it  Check for leaks (carefully) after starting

46. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Installing Injectors or Glow Plugs

47. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Glow Plug Service  Use a test light to check for voltage to the glow plugs during cycling  An inductive ammeter may be used to check current  low current may be caused by open glow plugs or supply circuit

48. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Glow Plug Resistance Test Check glow plug with an ohmmeter. Compare resistance to specifications.

49. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Glow Plug Replacement  Warning! Glow plugs may be hot!  Disconnect leads  Use a deep-well socket for removal  Coat glow plug threads with antiseize compound before installation  Screw into head by hand  Torque to specification

50. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injection Pump Service  Most service is done by specialty shops with special tools and test stands  External gasket, seal, and solenoid repairs may be made in a general shop

51. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injection Pump Test Stand Used to check injection pump operation

52. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only External Pump Repairs Leaks and faulty solenoids may be fixed without pump teardown

53. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Pump Removal  Set engine No. 1 piston at TDC  Observe pump timing marks  Disconnect battery  Remove injection lines, linkages, wires, and fasteners  Cap all lines  Remove pump

54. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Pump Removal Note the parts that must be disconnected before removal

55. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Parts Transfer This vacuum regulator valve must be reused on a new or rebuilt pump

56. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Installation  Align timing marks as you install pump  Torque fasteners and lines to specifications  Reconnect battery  Air bleeding may be necessary  The pump will be timed using various methods

57. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Adjustments  Injection pump timing  Cable/linkage adjustment  Curb idle speed  Cold idle speed  Maximum speed

58. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Injection Pump Timing Rotate the pump against the direction of rotation to advance timing; rotate the pump with the direction of rotation to retard timing

59. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Dial Indicator A dial indicator may be used to adjust timing on some vehicles

60. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Luminosity Meter Technician using a luminosity meter to detect combustion timing for adjustment

61. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Fuel Pressure Detector and Scope Transducer detects injection pulse

62. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Fuel Pressure Detector and Scope Low idle 1700 rpm, injection occurs sooner

63. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Cable/Linkage Adjustments

64. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Vacuum Valve Adjustment Carburetor angle gauge may be used to adjust the vacuum valve on this particular injection pump

65. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only External Adjustments

66. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Curb Idle Speed  Start engine and run to operating temperature  Connect a diesel tachometer  Adjust to specifications using the curb idle speed adjusting screw

67. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Diesel Tachometer Senses crankshaft damper position

68. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Cold Idle Speed  Usually performed on a hot engine  Connect a jumper wire from a battery feed to fast idle solenoid to raise engine speed  Raise engine speed to release solenoid plunger  Adjust to specifications, usually by turning solenoid plunger

69. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Cold Idle Speed Solenoid

70. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Maximum Speed  Limits highest attainable engine rpm  Position tachometer so that it can be read from driver’s seat  With the transmission in neutral or park and the brakes on, slowly press the accelerator to the floor  If maximum speed is not within specifications, turn adjusting screw on the injection pump

71. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Maximum Speed Adjustment

72. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Computerized Diesel Injection Service  Similar to other computer-controlled systems  Use self-diagnostics and scan tools  Use digital meters to check wiring, sensors and actuators