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In Common Rail Diesel vehicles, many fault codes are just a symptom and not the actual problem, so replacing failed components may not resolve the vehicles issues, or the same issue keeps recurring. This is where diagnostic tools are essential for resolving the basis of our fault codes.
Primarily, the most important and first job is a diagnostic test must be performed on Diesel vehicles with a suspected fuel system related issue. The basic step of obtaining a fuel sample and inspecting it. We can learn a lot from a visual inspection of a fuel sample.
Collect fuel samples from an area where water and particles are likely to gather, for example from the fuel filter base or the fuel tank pick up canister. By placing the fuel sample into a clear glass bottle of about 50-250ml (reagent sample bottles can be purchased from Specialist Tools Australia), you will be able to see if there are any contaminants within the fuel.
Using a small LED torch (work light), the light will make the metal particles appear larger and become visible to the naked eye. The bright shiny metal that may be seen with the LED torch is from wear to components such as injector spindles and the supply pump components.
Watch out
Darker red/orange particles may indicate rust. Rust is a very serious threat as it can form sub-micron particles which easily travel through the fuel filter and once inside the fuel system will cause an increasing amount of abrasive rust to form.
Allowing the sample to stand for a few hours may allow water to drop to the bottom of the bottle where it can easily be determined, and of course if there’s water in the fuel there may also be algae or other growths in the fuel.
Note: Keep in mind that up to 80 per cent of diesel fuel system faults are the result of water contaminated fuel in the system. Fitting new injectors when fuel is still contaminated will result in damage to all replaced parts in the fuel system, including new injectors. All fuel system components must be replaced and lines etc thoroughly cleaned of all contamination.
Some of the active tests and operational checks we can perform are injector compensations (feedback) levels, injector return volumes (magnet valve injectors) or return pressures (Piezo injectors). Injector operation isolation, function of EGR valve and operation of turbo VNT/VGT system.
Note: the EGR valve can often be temporarily blocked off as a test.
Diesel Injectors may also require removal for computerised testing.
Comprehensive Diesel and Petrol Compression and Cylinder Leak Test Kit (with adapters for an extensive range of vehicles including Japanese and European Compression Test Adaptors SA-7191CK)
Diesel engine compression and cylinder leakage tests are a very important primary diagnosis step, if you’re investigating any of the issues below in a diesel vehicle. If the vehicle is underperforming or experiencing a combination of the issues below, consider starting with a diesel engine compression test and you may want to perform a cylinder leakage test.
This kit can assist with diagnosing many common issues such as miss-fire or roughness when running, poor fuel economy or increased oil consumption, unusual smoke, unexplainable loss of power and excessive crank case pressure.
Generally, depending on individual vehicles each cylinder of the engine should measure within approx. 5-10 percent of each other. If the compression in the engine is in doubt, too low, too high or deviates too drastically from one cylinder to the next a cylinder leakage test can help locate the cause of the issue, or which specific internal engine fault is present.
Fuel Return Flow Kit Injector Test Common Rail Diesel SA-8392
This kit measures the volume of fuel returned from each injector on magnet valve (solenoid) injector systems. Low rail pressure in a common rail fuel system can often result in poor or no engine starting, rough running and poor acceleration or misfire.
A common reason for rail pressure loss can be caused by a faulty injector, which will see excessive fuel being returned to the fuel tank (also referred to as ‘back leakage’), with this excessive back leakage, rail pressure cannot be maintained, and the system cannot operate correctly. When engine is at operating temperature this can be more evident when starting and at idle as fuel pressure is directly related to engine cranking speed and fuel temperature.
And while a blocked or malfunctioning injector can send more fuel back to the tank, The SA-8392 kit makes both conditions obvious. It is comprehensive and can cater for up to eight injectors in one test. The tool is supplied with all instructions for testing magnet valve type injectors. Adaptors are included for Bosch, Siemens, Denso, and Delphi CRD systems.
Injector Return Pressure Measurement Tool for Diesel Common Rail New Piezo Injectors SA-2897K
The Injector Return tool kit for Piezo Injectors measures the pressure of the return fuel which is indicative of the condition of the injector.
The fuel rail pressure / injector operating pressure is generally greater on this system which allows for finer fuel spray. Typical operating voltages and current on most systems may be in the range of 100 – 400V and minus 20 to +20 Amps.
Typical resistance readings for the Piezo internal system is in the region of 150kOhm to 210kOhms (this is useful for identification of injector operation type). This is checked using a multi-meter.
Piezoelectric type injector Simplified operation: The internal construction of the Piezo injector varies from the Electromagnetic type. A stack of internal semiconductors expands when activated (Instead of being activated by a solenoid) which results in much quicker injector opening times.
This allows for an increased number of pre and post main injection operations for an individual cylinder combustion cycle which results in a smoother, cleaner and quieter engine. Most manufactures are now currently utilising this type of injector on modern vehicles.
Govoni Ultimate Seized Injector Extractor Kit – Master – Denso, Delphi, Bosch and Siemens – GO405
This kit will remove injectors stuck fast as a result of fouling caused by combustion leakage where the injector is locked in the recess and cannot be removed without a proper tool.
The universal supporting feet adjustment, on the fixing screws of the head, ensures its use in different levels (l/r) as well as the possibility to adjust the slippage of the two side bars.
The adjustment takes place both in height and width according to the conformity of the engine head. This kit can be used directly on the vehicle, with the engine mounted; its mechanical operation intact, and used in confined spaces or in the far back position near the passenger compartment.
Note: When injectors are removed, the sealing washer seat must be lightly cut, and a new washer installed, this is where our next kit is invaluable.
Diesel Injector Recess Reamer and Seat Cutter Kit – Denso, Delphi & Bosch etc – SA-3636L
This specialised tool has been developed to clean carbon from the injector bore and rectify injector seat non-conformity. For use on all modern common rail diesel engines.
Identify injector “blow-by” exits (The leaking of combustion gas from cylinder through the injector seating washer, the blow-by causes starting symptoms and poor running, excessive smoke, tar build-up, loss and noise of compression).
This 19-piece set is an extension of the SA-3636# range of Injector Seat Cutter and Cleaning tools.
It cleans and cuts the injector seat and nozzles and is a complete kit to service injector seat and nozzle as well as suiting a wide range of vehicles.
Note: Remember when injectors are removed, the sealing washer seat must be lightly cut, and a new washer installed.
There are many more timing tools, as well as other quality tools for the automotive professional available here or if you would like any assistance in finding the right tool call Specialist Tools Australia’s helpful team on 02-62804334 in Canberra