Testing and Failure Analysis.
Why Test?
Even with the OE manufacturer’s diagnostic equipment and service information, diesel injectors can be difficult to diagnose in the engine. Misfires and starting issues are far from the only symptoms injectors can cause. Modern diesels have the ability to compensate for worn injectors without the knowledge of the driver. This can give a false sense that they have a “good running engine.” Removing the injectors for testing helps separate them from other factors such as engine compression issues, poor fuel quality, wiring problems and faulty engine control modules. Here are some examples of when bench testing is a good option.
- Major engine repairs
- No access to a scan tool for diagnosis
- The manufacturer does not supply specifications such as return flow rate
- Limited scan data even with OE software
- Low engine compression in one or more cylinders
- Unable to perform testing at full load
Common Rail Injector Testing
Almost all modern diesel engines run common rail systems. At Prince George Fuel Injection, we test from the smallest displacement up to the current big bore engines found in many of todays class 8 trucks.
- Flow testing up to 36,000 psi
- Multiple return flow test taken with the injector static and under full load conditions
- Leak tests
- Coil resistance, inductance and insulation testing
- Response time measurements
- ISA testing of Bosch piezo injectors
Mechanical Injector Testing
From the first diesels to today’s small industrial engines, the mechanical injector has been around for a very long time. They come in many different types from all major fuel system manufacturers. More recent iterations have two springs, allowing for multiple opening pressures.
- Nozzle Opening Pressure
- Spray Pattern
- Leak Down
- Chatter
Free Testing!
Mechanical Injector Testing
Free Testing!
From the first diesels to today’s small industrial engines, the mechanical injector has been around for a very long time. They come in many different types from all major fuel system manufacturers. More recent iterations have two springs, allowing for multiple opening pressures.
- Nozzle Opening Pressure
- Spray Pattern
- Leak Down
- Chatter
HEUI Injector Testing
We currently test all makes of HEUI injectors found in Ford, International and Caterpillar applications. The added complexity of a high pressure oil system adds new challenges to testing. A long response time of the hydraulic control valve can lead to a delayed injection event which may cause increased emissions, hard starting, poor fuel economy and a misfire. These injectors can be found in many Navistar and Caterpillar engines as well as the 7.3L and 6.0L Ford PowerStroke.
- Internal Leak Test
- Response Time
- Flow Testing
- Coil Resistance and Inductance
Failure Analysis
Down time and repair costs are things that cannot always be avoided but repeat failures are. At Prince George Fuel Injection testing injectors is more that a simple pass or fail. We delve into the cause of failure, to uncover any underlying issues.