COMPETENCY BASED LEARNING MATERIAL

Sector:
AUTOMOTIVE/LAND TRANSPORT
Qualification:

Automotive Servicing NC II
Unit of Competency:

Service Engine Mechanical System

Module Title:

SERVICING DIESEL FUEL INJECTOR

TECHNICAL EDUCATION AND SKILLS DEVELOPMENT AUTHORITY
East Service Road, South Superhighway, Taguig, Metro Manila
 NATIONAL CERTIFICATE LEVEL 2
QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No. Unit of Competency Module Title Code

1. Service Starting System  Servicing Starting System ALT723307
2. Service Charging System  Servicing Charging System ALT723308
3. Service Engine Mechanical  Servicing Cooling System ALT723309a
System  Servicing Lubricating System ALT723309b
 Servicing Gasoline Fuel System ALT723309c
 Servicing Air Induction System ALT723309d
 Servicing Diesel Fuel ALT723309e
Injector
4. Service Clutch System  Servicing Clutch System ALT723310
5. Service Differential and Front  Servicing Differential and Front ALT723311
Axle Axle
6. Service Manual Steering System  Servicing Manual Steering ALT723312
System
7. Overhaul Manual Transmission  Pulling-out, Disassembling and ALT723313a
Checking Manual Transmission
 Assembling and Testing ALT723313b
Manual Transmission
8. Service Brake System  Identifying and Explaining ALT723314a
Hydraulic Brake System
Operations and Functions
 Servicing Brakes ALT723314b
 Overhauling Brake Systems ALT723314c
9. Service Suspension System  Servicing Suspension System ALT723315
 HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL

Welcome to the module “Servicing Diesel Fuel Injector”. This module contains training
materials and activities for you to complete.

The unit of competency "Service and Repair Engine Mechanical System" contains the
knowledge, skills and attitudes required for an Automotive Servicing course. It is one of
the Core Modules at National Certificate level (NC II).

You are required to go through a series of learning activities in order to complete each
learning outcomes of the module. In each learning outcome there are Information Sheets,
Resource Sheets and Reference Materials for further reading to help you understand better
the required activities. Follow these activities on your own and answer the self-check at the
end of each learning outcome. Get the answer key from your instructor and check your work
honestly. If you have questions, please don’t hesitate to ask your facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this learner's
guide because you have:
_ been working for some time
_ already completed training in this area.

If you can demonstrate to your trainer that you are competent in a particular skill, you don't
have to do the same training again.

If you feel you have some of the skills, talk to your trainer about having them formally
recognized. If you have qualification or Certificates of Competence from previous training,
show it to your trainer. If the skills you acquired are still relevant to the module, they may
become part of the evidence you can present for RPL.

At the end of this learning material is a learner’s diary, use this diary to record important
dates, jobs undertaken and other workplace events that will assist you in providing further
details to your trainer or assessors. A Record of Achievement is also provided for your
trainer to complete once you completed the module.

This learning material was prepared to help you achieve the required competency, in
servicing diesel fuel injector. This will be the source of information for you to acquire
knowledge and skills in this particular trade with minimum supervision or help from your
instructor. With the aid of this material you will acquire the competency independently and at
your own pace.

 Talk to your trainer and agree on how you will both organize the training of this unit.
Read through the learning guide carefully. It is divided into sections which cover all the
skills and knowledge you need to successfully complete in this module

 Work through all information and complete the activities in each section. Read the
information sheets and complete the self-check. Suggested references are included to
supplement the materials provided in this module.

 Most probably your trainer will also be your supervisor or manager. He/she is there to
support you and show you the correct way to do thing. Ask for help.

Code No. Date Developed Date Revised

SERVICING DIESEL FUEL INJECTOR Page 1
ALT723309D October 2004 March 1, 2006
  Your trainer will tell you about the important things you need to consider when you are
completing activities and it is important that you listen and take notes.

 You will be given plenty of opportunity to ask questions and practice on the job. Make
sure you practice your new skills during regular work shifts. This way you will improve
both your speed and memory and also your confidence.

 Talk to more experienced workmates and ask for their guidance.

 Use self-check questions at the end of each section to test your own progress.

 When you are ready, ask your trainer to watch your perform the activities outlined in this
learning material.

 As you work through the activities, ask for written feedback on your progress.
Your trainer keeps feedback/pre-assessment reports for this lesson. When you
have successfully completed each element, ask your trainer to mark on the reports
that you are ready for assessment.

 When you have completed this learning material and feel confident that you have had
sufficient practice, your trainer will arrange an appointment with registered assessor to
assess you. The results of your assessment will be recorded in your competency
Achievement Record.

Code No. Date Developed Date Revised Page 2

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
Qualification : Automotive Servicing NC II

Unit of Competency : Service and Repair Engine Mechanical System

Module Title : Servicing Diesel Fuel Injector

Introduction :

More and more demands are being made on modern internal-combustion engines. On
the one hand they must become more powerful and quieter, while on the other they must at the
same time be cleaner and use less fuel. Particularly in the diesel engine sector, tremendous
advances have been made in the past few years thanks to the ongoing developments in fuel-
injection technology.

This module contains information and practices in servicing diesel fuel injector. It
includes definite and clear instructions in overhauling and calibrating/installing fuel injector.

You need to complete this module by learning the theories and principles required,
closely coupled with the practical activities to master the skill required in this module. Desirable
values and attitudes must also be taken into consideration.

This module consists of two learning outcomes. Each outcome contains learning
activities for both knowledge and skill, supported with information sheets; self-check and job
operation sheets gathered from different sources. Before performing the practical activities,
read the information and operation sheets provided and answer the self-check to confirm that
you are equipped with the knowledge necessary to perform the skill portion of this module

Upon completion of this module, you have to subject yourself to your instructor for
assessment. You will be given a certificate of completion as a proof that you have met the
standard requirement (knowledge and skill). The assessment could be made in different
methods as prescribed in the competency standard.

Learning Outcomes:

At the end of this module you will be able to:

1. Overhaul diesel fuel injector

2. Calibrate/install injector

Assessment Criteria:

1.1 Tools, materials and equipment are prepared according to service manual.
1.2 Components parts are identified.
1.3 Function and uses of diesel fuel injector component are explained.
1.4 Safe handling of parts is observed.
1.5 Standard specification is determined.

2.1 Tools, materials and equipment needed in calibrating and installing diesel fuel
injector are identified.
2.2 Calibration and installation procedures are discussed and explained.
2.3 Testing sequence is observed in accordance with in service manual specification

Code No. Date Developed Date Revised Page 3

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
Qualification : Automotive Servicing NC II

Module Title : Servicing Diesel Fuel Injector

Learning Outcome #1 : Overhaul diesel fuel injector

Assessment Criteria:

1. Tools, materials and equipment are prepared according to service manual.

2. Components parts are identified.
3. Function and uses of diesel fuel injector components are explained.
4. Safe handling of parts is observed.
5. Standard specification is determined.

Resources:
th
1. Automotive Mechanics, 10 ed. By Willan H. Crouse and Donald Anglin,, pp 290-302
2. Automotive Technology, by Jack Erjavec, pp. 290 – 298

Code No. Date Developed Date Revised Page 4

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
LEARNING EXPERIENCES
Learning Outcome #1: Overhaul diesel fuel injector
Learning Activities Special Instructions

1.1 Read the information sheet “Fuel Injectors”  Inspect the appearance of a diesel fuel
to become familiar with its parts and injector found in your shop.
functions including its operation and location  Go to your learning resource center
in the engine. and view the video on how a diesel
fuel injector works.
a. Reading information/reference book
You may also surf the internet for more
information.

b. Accomplish the Self-Check.

1.2 Describe and identify diesel fuel injector

parts:
 injection nozzles
 fuel filters
 timing device
 governor
 injection pump

a. Reading from reference books and a. Read: Automechanics by Crouse

answering Self-Check and Anglin, pp. 210-222; Automotive
Technology by Jack Ervajec, pp.
After answering, get the answer key from 290-298
your instructor and check your work
honestly.

b. Reading Information Sheet about b. Answer Self-Check No. 1. After

Description and answering Self-Check answering, get the answer key from
your instructor and check your work
honestly.

Code No. Date Developed Date Revised Page 5

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
 Information Sheet LO1-1
Fuel Injectors
1. A fuel injector is nothing but an
electronically controlled valve. It is
supplied with pressurized fuel by the fuel
pump in your car, and it is capable of
opening and closing many times per
second.

Figure 1. A typical fuel injector.

2. When the injector is energized, an

electromagnet moves a plunger that
opens the valve, allowing the pressurized
fuel to squirt out through a tiny nozzle.
The nozzle is designed to atomize the
fuel -- to make as fine a mist as possible
so that it can burn easily.

Figure 2. Fuel injector squirting pressurized fuel

through the nozzle.

Code No. Date Developed Date Revised Page 6

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
3. The amount of fuel supplied to the engine
is determined by the amount of time the
fuel injector stays open. This is called the
pulse width, and it is controlled by the
electronic control unit (ECU).

Figure 3. Fuel injectors mounted in the intake

manifold of the engine
4. The injectors are mounted in the intake
manifold so that they spray fuel directly at
the intake valves. A pipe called the fuel
rail supplies pressurized fuel to all of the
injectors.

Figure 4. Three of the injectors. The fuel rail is the

pipe on the left.

In order to provide the right amount of fuel, the engine control unit is equipped with a whole lot
of sensors. Let's take a look at some of them.

Sensors

In order to provide the correct amount of fuel for every operating condition, the engine control
unit (ECU) has to monitor a huge number of input sensors. Here are just a few:

 Mass airflow sensor - Tells the ECU the mass of air entering the engine
 Oxygen sensor(s) - Monitors the amount of oxygen in the exhaust so the ECU can
determine how rich or lean the fuel mixture is and make adjustments accordingly
 Throttle position sensor - Monitors the throttle valve position (which determines how
much air goes into the engine) so the ECU can respond quickly to changes, increasing or
decreasing the fuel rate as necessary
 Coolant temperature sensor - Allows the ECU to determine when the engine has
reached its proper operating temperature
 Voltage sensor - Monitors the system voltage in the car so the ECU can raise the idle
speed if voltage is dropping (which would indicate a high electrical load)
 Manifold absolute pressure sensor - Monitors the pressure of the air in the
intake manifold
Code No. Date Developed Date Revised Page 7
ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
 The amount of air being drawn into the engine is a good indication of how much power it
is producing; and the more air that goes into the engine, the lower the manifold pressure,
so this reading is used to gauge how much power is being produced.
 Engine speed sensor - Monitors engine speed, which is one of the factors used to
calculate the pulse width

There are two main types of control for multi-port systems: The fuel injectors can all open at the
same time, or each one can open just before the intake valve for its cylinder opens (this is called
sequential multi-port fuel injection).

The advantage of sequential fuel injection is that if the driver makes a sudden change, the system
can respond more quickly because from the time the change is made, it only has to wait only until
the next intake valve opens, instead of for the next complete revolution of the engine.

Engine Controls and Performance Chips

The algorithms that control the engine are quite complicated. The software has to allow the car to
satisfy emissions requirements for 100,000 miles, meet EPA fuel economy requirements and
protect engines against abuse. And there are dozens of other requirements to meet as well.

The engine control unit uses a formula and a large number of lookup tables to determine the pulse
width for given operating conditions. The equation will be a series of many factors multiplied by
each other. Many of these factors will come from lookup tables. We'll go through a simplified
calculation of the fuel injector pulse width. In this example, our equation will only have three
factors, whereas a real control system might have a hundred or more.

Pulse width = (Base pulse width) x (Factor A) x (Factor B)

In order to calculate the pulse width, the ECU

RPM
first looks up the base pulse width in a lookup
table. Base pulse width is a function of engine Load
speed (RPM) and load (which can be calculated 1
from manifold absolute pressure). Let's say the 3
1,000
engine speed is 2,000 RPM and load is 4. We 1
find the number at the intersection of 2,000 and 22,000
4, which is 8 milliseconds. 23
443,000
36
684,000
5
49
In the next examples, A and B are parameters 10
812
that come from sensors. Let's say that A is 12 A Factor A B Factor B
coolant temperature and B is oxygen level. If 15
160
coolant temperature equals 100 and oxygen
20 1.2
level equals 3, the lookup tables tell us that
025
Factor A = 0.8 and Factor B = 1.0. 1.1
1.0
150
1.0
1.0
275
0.9
1.0
3100 0.8 4 0.75
1.0
So, since we know that base pulse width is a function of load and RPM, and that pulse width =
(base pulse width) x (factor A) x (factor B), the overall pulse width in our example equals:
8 x 0.8 x 1.0 = 6.4 milliseconds

Code No. Date Developed Date Revised Page 8

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
From this example, you can see how the control system makes adjustments. With parameter B
as the level of oxygen in the exhaust, the lookup table for B is the point at which there is
(according to engine designers) too much oxygen in the exhaust; and accordingly, the ECU cuts
back on the fuel.

Real control systems may have more than 100 parameters, each with its own lookup table.
Some of the parameters even change over time in order to compensate for changes in the
performance of engine components like the catalytic converter. And depending on the engine
speed, the ECU may have to do these calculations over a hundred times per second.

Performance Chips

This leads us to our discussion of performance

chips. Now that we understand a little bit about
how the control algorithms in the ECU work,
we can understand what performance-chip
makers do to get more power out of the
engine.

Performance chips are made by aftermarket

companies, and are used to boost engine
power. There is a chip in the ECU that holds
all of the lookup tables; the performance chip
replaces this chip. The tables in the
performance chip will contain values that result
in higher fuel rates during certain driving
conditions.

For instance, they may supply more fuel at full throttle at every engine speed. Since the
performance-chip makers are not as concerned with issues like reliability, mileage and
emissions controls as the carmakers are, they use more aggressive settings in the fuel maps of
their performance chips.

Code No. Date Developed Date Revised Page 9

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
 Information Sheet LO1-2
Diesel Engine and Fuel-Injection Service

Servicing Diesel Engines and Fuel Systems

Basic servicing procedures on diesel engines are similar to those for spark-ignition engines.
Table 1 is a diesel fuel-injection system trouble-diagnosis chart.

Table 1. Diesel Fuel Injection System Trouble Diagnosis Chart

Complaint Possible Cause Check or Correction

1. Engine cranks normally but will a. Incorrect or dirty fuel Flush system—use correct fuel
not start b. No fuel to nozzles or injection Check for fuel to nozzles
pump
c. Plugged fuel-return line Check return line, clean
d. Pump timing off Retime
e. Inoperative glow plugs. Incorrect
starting procedure, or internal
engine problems
2. Engine starts but stalls on idle a. Fuel low in tank Fill tank
b. Incorrect or dirty fuel Flush system—use correct fuel
c. Limited fuel to nozzles or Check for fuel to nozzles and to
injection pump pump
d. Restricted fuel return line
e. Idle incorrectly set Check return line, clean
f. Pump turning off Reset idle
g. Injection-pump trouble Retime
h. Internal engine problems Install new pump
3. Rough idle, no abnormal noise a. Low idle incorrect Adjust
or smoke b. Injection line leaks Fix leaks
c. Restricted fuel-return line Clear
d. Nozzle trouble Check, repair or replace
e. Fuel supply pump problem Check, replace if necessary
f. Uneven fuel distribution to Selectively replace nozzles until
nozzles condition clears up
g. Incorrect or dirty fuel Flush system—use correct fuel
4. Rough idle with abnormal noise a. Injection pump timing off Retime
and smoke b. Nozzle trouble Check cylinders in sequence to find
defective nozzle
5. Idle okay but misfires as throttle a. Plugged fuel line Replace filter
opens b. Injection pump timing off Retime
c. Incorrect or dirty fuel Flush system—use correct fuel
6. Loss of power a. Incorrect or dirty fuel Flush system—use correct fuel
b. Restricted fuel-return line Clear
c. Plugged fuel-tank vent Clean
d. Restricted fuel supply Check fuel lines, fuel supply pump,
injection pump
e. Plugged fuel filter Replace filter
f. Plugged nozzles Selectively test nozzles, replace as
necessary
g. Internal engine problems, loss of
compression, compression leaks
7. Noise—“rap” from one or more a. Air in fuel system Check for cause and correct
cylinders b. Gasoline in fuel system Replace fuel
c. Air in high-pressure line Bleed system
d. Nozzle sticking open or with low Replace defective nozzle
opening pressure
e. Engine problems
8. Combustion noise with a. Timing off Reset
excessive black smoke b. Injection pump trouble Replace pump
c. Nozzle sticking open Clean or replace
d. Internal engine problems
Code No. Date Developed Date Revised Page 10
ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
Procedures in Servicing Various Diesel Fuel-Systems.

The transfer pump or fuel-supply pump (Figures 5 and 6) is similar to the mechanical fuel pump
used in carbureted spark-ignition engines. Air in the fuel-return line of a diesel engine can be
caused by a leak in the line between the pump and the fuel tank. This is the vacuum side of the
pump and will draw in air.

Figure 5. Typical fuel systems for automotive diesel engine. (Ford Motor Company)

Modern engines are fitted with injection systems designed to deliver and properly atomize
diesel fuel which has a viscosity of approx. 8 centistokes, common vegetable oils are 10-20
times more viscous (thick) and trying to spray it through an injector designed for a fluid so much
less viscous is similar to trying to spray butter through a feeding bottle. An improper spray
pattern will result in incomplete combustion. Incomplete combustion will result in carbon
deposits being formed in the engine which will destroy the engine. There are several ways to
reduce the viscosity of vegetable oil. The simplest is simply heating it up, as you can see from
the information presented in Table 1, when vegetable oil has been heated to 160ºF its viscosity
is very close to that of petroleum diesel.

Servicing Injection Lines and Fittings

Injection lines in diesel-engine fuel-injection systems are also called high-pressure fuel lines,
injection tubes and injection pipes. They carry fuel under high pressure from the injection pump
to the ignition nozzles. Figure 5 and 6 show the various shapes of injection lines between the
injection pump and the nozzles.

Code No. Date Developed Date Revised Page 11

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
 Figure 6. Fuel systems for a six-cylinder diesel engine using a rotary-distributor injection pump. (Chrysler
Corporation)

When the line requires replacement, always install the line specified by the vehicle
manufacturer. Variations from specified length and internal diameter may cause engine
troubles. New lines are preformed. Avoid twisting or bending them out of shape during
installation.

Caution: Relieve the line pressure and cover the connection with a shop towel before loosening
any fitting.

Whenever lines are disconnected, cap the lines, nozzles and pump fittings. This prevents dirt
from entering the fuel system. Cleanliness is very important when working on the diesel fuel
system. A particle so small as to be almost invisible can clog an injection nozzle.

Fuel Filter Service

The fuel filter (Figure 23-3) is located in the low-pressure fuel line from the fuel tank to the
injection pump. The filter element is similar to filters used in engine lubricating systems. The fuel
must pass through the filter element which traps any dirt particles. Replace the filter periodically
as recommended by the manufacturer.

Code No. Date Developed Date Revised Page 12

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
Injection Nozzle Service

Never remove an injection nozzle from the engine except for service or replacement. The
following indicate injection nozzle trouble:

1. One or more cylinder knocking

2. Loss of power
3. Smoky black exhaust
4. Engine overheating
5. Excessive fuel consumption

One way to check injection nozzles is to run the engine at fast idle. Loosen the connector at
each nozzle in turn, one at a time. Wrap a cloth around the connection before you loosen it to
keep fuel from spurting out. If loosening the connector causes engine speed to drop, the nozzle
is probably working normally. If the engine speed remains the same, the nozzle is not working
properly. Clogged holes are preventing fuel delivery or causing an improper spray pattern.

Some manufacturers recommend a spray test

of the detached injection nozzle. This requires
a nozzle tester, which is a special hydraulic
pump and pressure gauge. Attach the nozzle
and apply pressure. The fuel should spray in
an acceptable pattern (Fig. 7) when the
specified pressure is reached. Releasing the
pressure should stop the spray abruptly
without any drip from the nozzle.

Caution: Direct the spray from the nozzle into

a suitable container. Do not allow the spray to
hit your skin. The pressure is high enough to
force fuel oil through the skin. You can be
seriously injured because the oil could cause Figure 7. Injection-nozzle spray pattern. (Ford Motor
Corporation)
an infection.

If the engine misses at all speeds and produces a puff of exhaust smoke each time it misfires,
an injection nozzle is probably sticking open. The nozzle can be disassembled and cleaned.
Some manufacturers recommend replacing a faulty nozzle. If you disassemble a nozzle, do not
damage the tip or enlarge the holes. This can cause leakage and other troubles.

Figure 8. Disassembled diesel-engine fuel injection nozzle. (Ford Motor Corporation)

Code No. Date Developed Date Revised Page 13

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
 Operation Sheet LO1-1
Overhauling Diesel Fuel Injector

1. Remove the fuel injectors from the engine.

Cover the injectors with shop towel before
loosening to avoid squirting highly-
pressurized fuel towards you.

2. Examine the appearance of the nozzle tips

of each injector.

3. If the fuel injector is dirty, it must be

cleaned in a container with highly volatile
liquid such as gasoline or fuel injector
cleaner.

4. Follow all safety precautions and operating instructions in the shop to avoid injury, damage
and fire.

5. If the injector is clogged, disassemble it carefully without damaging the parts. (See figure 8).

Fuel Injector Disassembly

 Clamp the injector by its nozzle holder in a suitable vise.

 Remove the nozzle cap, nozzle cap nut, and gasket using an appropriate wrench
 Remove the nozzle holder together with the nozzle body
 Remove the nozzle needle pin from the nozzle body without touching the mating
surfaces with fingers
 Remove the retaining nut
 Use a flat screwdriver to loosen the spring cap, then remove the pressure spring
 Remove the nozzle holder from the vise and take the pressure pin out.

6. If the injector is severely damaged and no replacement parts are available, replace it with a
new one.

7. Clean the fuel lines connecting the injectors.

8. Clean the fuel return line.

9. Assemble the injectors, install, bleed and test.

Code No. Date Developed Date Revised Page 14

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
Qualification : Automotive Servicing NC II

Module Title : Servicing Diesel Fuel Injector

Learning Outcome #2 : Calibrate and install diesel fuel injector

Assessment Criteria:

1. Tools, materials and equipment needed in calibrating and installing diesel fuel injector
are identified.
2. Calibration and installation procedures are discussed and explained.
3. Testing sequence is observed in accordance with in service manual specification.

Resources:
th
1. Automotive Mechanics, 10 ed. By Willan H. Crouse and Donald Anglin,, pp 290-302
2. Automotive Technology, by Jack Erjavec, pp. 290 – 298

Code No. Date Developed Date Revised

ALT723309D October 2004 March 1, 2006 Page 15
SERVICING DIESEL FUEL INJECTOR
LEARNING EXPERIENCES
Learning Outcome #2: Calibrate and install diesel fuel injector
Learning Activities Special Instructions

1.1 Read the information sheet “Fuel Injectors”  Inspect the appearance of a diesel fuel
to become familiar with its parts and injector found in your shop.
functions including its operation and  Go to your learning resource center
location in the engine. and view the video on how a diesel
fuel injector works.
b. Reading information/reference book
You may also surf the internet for more
information.

b. Accomplish the Self-Check.

1.2 Identify and describe diesel fuel injector

parts:
 injection nozzles
 fuel filters
 timing device
 governor
 injection pump

b. Reading from reference books and a. Read: Automechanics by Crouse and

answering Self-Check Anglin, pp. 210-222; Automotive
Technology by Jack Ervajec, pp. 290-
After answering, get the answer key from 298
your instructor and check your work
honestly.

c. Reading Information Sheet about b. Answer Self-Check No. 1. After

Description and answering Self-Check answering, get the answer key from
your instructor and check your work
honestly.

Code No. Date Developed Date Revised Page 16

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
 Operation Sheet LO2-1
Calibrating Diesel Fuel Injector
To calibrate a diesel fuel injector, you need the following tools, equipment and materials.

1. High-pressure pump
2. Pressure gauge
3. Injection nozzles
4. Screwdriver
5. Set of wrenches
6. Table vise
7. Clean shop cloth

Procedure:

1. Disassemble the fuel injector

2. Clean parts
3. Replace nozzles
4. Assemble the parts
5. Perform a injector pressure test
 Set the injector to the high-pressure pump
 Operate the pump and observe the pressure gauge
 Read the pressure gauge just as the pressure begins to drop

Note: The nozzle is operating properly if you can hear a swishing sound. The opening
2
pressure is 105-125 kg/cm . If the opening pressure is not as specified, adjust the
pressure by tightening or loosening the pressure spring using a screwdriver.

6. Perform a leakage test

2
 While maintaining a pressure of 10-20 kg/cm lower than the opening pressure,
check that there is no dripping fuel from the injection hole or around the retaining nut.
If the nozzle drips within ten seconds, clean, overhaul or replace the nozzle assembly.

7. Perform a spray pattern test

 The injection nozzle shudders at certain pumping speed between 15-60 times (old
nozzle) or 30-60 times (new nozzle) per minute.
 Check the spray pattern while the nozzle is shuddering. If the spray pattern is not
correct (refer to figure 7) the nozzle must be cleaned or replaced.

8. Install the injectors

Code No. Date Developed Date Revised Page 17

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
 PERFORMANCE TEST

Learner’s Name Date:

Test Attempt
st nd rd
Competency: Servicing Diesel Fuel Injector 1 2 3

Directions: OVERALL EVALUATION

Level
PERFORMANCE LEVELS
CALL INSTRUCTOR, ask instructor Achieved
to assess your performance in the 4 – Can perform this skill without supervision and with
following critical task and initiative and adaptability to problem situations.
performance criteria below. 3 – Can perform this skill satisfactorily without
assistance or supervision.
You will be rate based on the overall
2 – Can perform this skill satisfactorily but requires some
evaluation on the right side. assistance and/or supervision.

1 – Can perform parts of this skill satisfactorily, but

requires considerable assistance and/or supervision.

Instructor will initial level achieved.

PERFORMANCE STANDARDS Yes No N/A

For acceptable achievement, all items should receive a “Yes”
or “N/A” response.
1. Were tools, materials and equipment prepared according to service
manual?
2. Were components identified?

3. Were diesel injector components parts and functions explained?

4. Were tools handled safely?

5. Were standard specifications determined?

6. Were tools, materials and equipment needed in calibrating and
installing diesel fuel injector identified?
7. Were procedures in installation and calibration discussed and
explained?
8. Is testing sequence observed in accordance with service manual
specification?

Code No. Date Developed Date Revised Page 18

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
Learner’s Diary

DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing further
details to an Assessor.
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Code No. Date Developed Date Revised Page 19

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
Record of Achievement

Module: SERVICING DIESEL FUEL INJECTOR

LO #1 : Overhaul Diesel Fuel Injector

Performance Criteria:

1. Tools and Equipment prepared according to kind and size

2. Functions and Uses of Turbo Charger components are explained
3. Component parts are identified
4. Safe handling of parts are observed
5. Standard specification is determined

Comments:

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Learner has satisfied the above performance criteria.

Learner’s signature: .......................................................................
Trainer’s signature: ........................................................................
Date:...............................................................................................

Code No. Date Developed Date Revised Page 20

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
Record of Achievement

Module: SERVICING DIESEL FUEL INJECTOR

LO#2 : Calibrate/Install Injector

Performance Criteria:

1. Tools and equipment needed in calibrating and installing diesel fuel injector are identified
2. Calibration and installation procedures are discussed and explained
3. Testing sequence is observed in accordance within service manual specification

Comments:

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Learner has satisfied the above performance criteria.

Learner’s signature: .......................................................................
Trainer’s signature: ........................................................................
Date:...............................................................................................

Code No. Date Developed Date Revised Page 21

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006
TERMS AND DEFINITIONS
Coolant temperature sensor:
A sensor located at the bottom of the radiator which is connected to the temperature
gauge.
ECU:
Acronym for "Electronic Control Unit"
Engine speed sensor:
In most cases, a magnetic pick-up that scans the flywheel teeth and produces one output
signal per scanned tooth, or a Hall generator in the distributor, whose signals are passed
to the electronic control unit
Fuel rail:
A manifold tube feeding the injectors in a fuel injection system. A special manifold
designed to provide a large reservoir of pressurized fuel for the fuel injectors, which are
attached between the rail and the intake runners or the cylinder head. The fuel rail also
serves as a mounting place for the fuel damper (if equipped) and the fuel pressure
regulator
Injector:
Refers to the pump system (used in a fuel injection system) that squirts or injects a
measured amount of gasoline into the intake manifold in the vicinity of the intake valve.
In the diesel engine fuel is injected directly into the cylinder. In a Continuous Injection
System (CIS), the injectors atomize the continuous flow of fuel injected under pressure
into the intake ports of the engine; a valve in the injector nozzle stops the flow of fuel
when fuel pressure drops below a certain point; in a CIS, the quantity of fuel is regulated
by the fuel distributor's metering unit; in other fuel injection systems, the fuel system
delivers a constant supply of fuel at a constant pressure to the injector, and an electronic
sensing and control system produces electrical current pulses of appropriate duration to
hold open the injector solenoid valves; as fuel pressure is held constant, varying the
pulse duration increases or decreases the amount of fuel passed through the injectors.
Mass airflow meter:
(MAF) device for measuring the mass flow of air into an engine.
Manifold absolute pressure sensor:
(MAP) A sensor which monitors the engine's intake manifold pressure and transmits the
data to the engine controller. A pressure-sensitive disk capacitor used to measure air
pressure inside the intake manifold. The Map sensor sends a signal to the computer
which uses this information to determine load conditions so it can adjust spark timing and
fuel mixture. Also called manifold pressure sensor or pressure differential sensor
Nozzle:
A thin hollow tube; a jet or hole at the end of a pipe.
Oxygen sensor:
A pollution control device which measures the amount of oxygen in the exhaust stream
and sends that information the ECM. It controls the fuel-air mixture entering the engine.
Also called a lambda sensor, exhaust oxygen sensor, or an O2 sensor
Throttle position sensor:
(TPS) A potentiometric fuel injection switch with two contacts for the two end positions of
the throttle valve, which sends a signal to the electronic control unit when the throttle
valve is closed (idle) or wide open (full load). The sensor wiper position is proportional to
throttle position. The computer uses this information to control fuel flow
Sensor:
An electronic detection device that receives and reacts to a signal, such as a change in
voltage, temperature or pressure.

Code No. Date Developed Date Revised Page 22

ALT723309D SERVICING DIESEL FUEL INJECTOR October 2004 March 1, 2006