CLEANING DIESEL INJECTORS
1. WHEN SHOULD DIESEL INJECTORS BE CLEANED AND WHY?
Various impurities can accumulate in diesel fuel and over time these can cause malfunctions or affect the performance of the diesel injectors.
Cleaning diesel injectors should not be overlooked. It's a good idea to equip yourself with the right maintenance tools and to get help from professional technicians from time to time.
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2. HOW CAN YOU TELL IF THE INJECTORS ARE DIRTY?
The presence of impurities in diesel is somewhat natural.
It’s important to pay attention and recognise the signals that indicate when it is time to clean the injectors.
How can you tell if an injector needs cleaning?
Here are some clues:
- difficulty in starting the engine
- increased fuel consumption
- drop in performance
- engine stalling at low engine speeds
- black exhaust fumes
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3. HOW DO YOU CLEAN DIESEL INJECTORS?
Careful and regular engine maintenance is certainly the first step to avoid damage or unfortunate incidents.
You should call in a trusted mechanic or a professional pump specialist periodically to disassemble and reassemble the injectors.
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4. HOW TO DISASSEMBLE AND CLEAN DIESEL INJECTORS
REDAT S.p.A. has a wide range of toolboxes for the correct disassembly and assembly of diesel injectors, these are useful for cleaning the components thoroughly.
Each toolbox contains specific tools for a particular type of injector. All the tools we use are designed and tested in our workshop, so we can provide our customers with a complete kit with everything they need to guarantee the quality and efficiency of disassembly, reassembly and, if necessary, repair of the injector.
Specific applications for each kit and instructions on how to use the equipment correctly can be found in our catalogue.
Click on this link: https://www.redat.com/en/content/15-youtube, to watch videos on how to assemble and disassemble some types of diesel injectors.
REDAT S.p.A. also supplies a wide range of tools for servicing diesel injectors, which you can find in our catalogues:
https://www.redat.com/en/51-diesel-catalogs
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5. HOW TO CHECK DIESEL INJECTORS
How do you check a diesel injector? Once the part has been removed from the engine, it must first be disassembled (see the video tutorial) to check its condition and replace any worn parts, such as the O-rings. The second step is to check the nozzle - the most important and delicate part of the injector.
In our workshop, we use a precision instrument called a boroscope to inspect diesel nozzles in detail. The boroscope is used to check inside for any residues or foreign bodies that may be clogging the holes. The injector's performance may be impaired if these are clogged.
Watch our boroscope in operation in the new video on REDAT S.p.A.'s YouTube channel: https://www.youtube.com/watch?v=h9rMn9uq1Ms&t=14s
The boroscope can be found in our catalogue:
https://www.redat.com/ZenCataloghi/Caterpillar%20-%20Perkins_99180713141057_01/#p=260
Our Diesel injector cleaning toolboxes contain a wire for cleaning the nozzle holes and removing any dirt. If cleaning is successful, the injector can be reassembled and used again. However, if the dirt is too heavy and resistant, a new nozzle must be bought and installed inside the diesel injector.
If necessary, the metal parts of the injector can be cleaned individually in an ultrasonic cleaning tank to make them as shiny and clean as new. It is advisable to replace the O-rings and gaskets each time they are removed, as they are made of a more delicate material than metal and are much cheaper.
We usually use our hook kit to remove them more easily and our cone kit to insert new gaskets.
Watch the O-Ring replacement kit video: https://www.youtube.com/watch?v=5feaGyaqHYE&t=95s
Hooks for removing O-rings can be found in our catalogue: https://www.redat.com/ZenCataloghi/Caterpillar%20-%20Perkins_99180713141057_01/#p=265
Cones for inserting O-rings can be found in our catalogue: https://www.redat.com/ZenCataloghi/Caterpillar%20-%20Perkins_99180713141057_01/#p=80
Cleaning the delivery connector filters on Denso injectors should not be overlooked. This is where diesel enters the injector and dirt can cause malfunctions. The filters must be removed from the injector body for cleaning. We recommend using a specific tool from our toolbox to remove them easily without damaging the injector.
We demonstrate how to do this in the video tutorial about the correct replacement of Denso filters.
Denso injector filter replacement video: https://www.youtube.com/watch?v=Zbr8L5riiJI
The toolbox for the correct disassembly of Denso filters can be found in our catalogue:
https://www.redat.com/ZenCataloghi/Denso_99180629112933_01/#p=126
All the spare parts and materials listed above, which we usually use, are available on our website, in our warehouse and in our workshop. Once the injector has been cleaned and reassembled, we recommend performing a bench test to check that it is working properly. If no further problems are found, the injector has been fully reconditioned.
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6. NOZZLE CLEANING KIT
If residues are found to be clogging the holes when the nozzle is inspected with a boroscope, a cleaning toolbox is needed.
REDAT S.p.A. has several different types of toolboxes designed for nozzle maintenance, which contain a nozzle cleaning wire.
Here are some of our products for cleaning nozzles, for example from the Caterpillar
- Perkins catalogue:
1: Nozzle cleaning toolkit 4 010 812: https://www.redat.com/ZenCataloghi/Caterpillar%20-%20Perkins_99180713141057_01/#p=260
2: Nozzle cleaning wire: https://www.redat.com/ZenCataloghi/Caterpillar%20-%20Perkins_99180713141057_01/#p=260
3: Boroscope for cleaning nozzles: https://www.redat.com/ZenCataloghi/Caterpillar%20-%20Perkins_99180713141057_01/#p=260
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7. INJECTOR CLEANING KITS
REDAT S.p.A. supplies various tools and equipment for cleaning Diesel injectors, including those in the assembly and disassembly kits. These tools are suitable for any type of injector and can be found in all our Diesel catalogues: Bosch, Caterpillar, Denso, Delphi, Cummins, Siemens and Unit Injector.
The ultrasonic cleaning tank is one of the devices for cleaning injectors, this can be used to wash metals and alloys (for plastics it is not recommended due to the tank's high operating temperature). Designed primarily for cleaning all types of injectors and pumps, it is indispensable for all Diesel and Common Rail systems. It ensures the perfect cleaning and removal of oil, grease and carbon residues.
Here are some of our products for cleaning injectors from the Caterpillar catalogue, which can also be found in all other Diesel catalogues: Bosch, Denso, Delphi, Cummins, Siemens and Unit Injector:
Ultrasonic cleaning tank for metal 4 021 047
https://www.redat.com/ZenCataloghi/Caterpillar%20-%20Perkins_99180713141057_01/#p=259
Brass brush 4 021 639 https://www.redat.com/ZenCataloghi/Caterpillar%20-%20Perkins_99180713141057_01/#p=250
Once the O-rings and gaskets have been replaced and all worn or damaged parts of the diesel injector have been checked, cleaned, replaced and finally bench-tested, the injector is fully reconditioned and can be refitted in its seat inside the engine.
If necessary, you can also clean the internal seat using our reamers kit for cleaning the internal seat of Common Rail nozzle holders and pump-injectors.
The reamers kit for cleaning the internal seat of nozzle holders can be found in our catalogue:
https://www.redat.com/ZenCataloghi/Denso_99180629112933_01/#p=199
You can find all the kits, spare parts and accessories that we use in our workshop for the correct and efficient cleaning of injectors, to guarantee an efficient and high-quality service for our customers, on our website www.redat.com by entering the relevant code from our catalogues, or by sending an e-mail to [email protected]
To find out our product prices, you can click on the "request a quote" button in the e-commerce section of our website, e-mail us or simply set up an account with a personal password to see all available products and their prices, quickly and easily. Just send an e-mail to [email protected] with your name and account request.
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For further information:
Tel.: +39 011 969 1111
E-mail: [email protected]