Injector needle valve Components are often prone to failure due to long-term exposure to high temperature and pressure in harsh working conditions. One of the most common issues is the needle getting stuck inside the valve body, which can lead to serious damage or even complete failure of the component. Even if these parts can be repaired, the process is time-consuming and labor-intensive, and there's no guarantee that the repaired parts will perform as well as new ones. Experienced technicians and maintenance personnel have developed five practical tips through years of hands-on experience, which can significantly reduce the risk of the needle valve becoming seized or stuck.
First, during injector maintenance, it's crucial to thoroughly clean all disassembled parts. Don't just focus on the needle and valve assembly—make sure to clean other components such as the pressure spring, spring nut, adjustment screw, and tappet as well. If dirt or contaminants remain on these parts, they can be pushed up by the tappet and interfere with the needle’s movement, leading to sticking.
Second, never remove the return oil pipe. This pipe helps drain any leaked diesel from the needle valve and valve body back into the low-pressure fuel circuit, reducing waste and maintaining fuel cleanliness. Removing it not only prevents the reuse of spilled fuel but also allows dust and debris to enter the injector through the connection hole, increasing the chance of the needle valve becoming stuck. Some people try to block the hole, but this is even worse, as it can cause pressure buildup and lead to internal damage.
Third, after installing the high-pressure tubing, connect the low-pressure fuel circuit first, then the high-pressure line to the fuel pump. Set the throttle to maximum fuel supply, turn the crankshaft, and run the fuel injection pump until the high-pressure tubing has been primed 5–10 times. Then, connect the high-pressure line to the fuel injector. This ensures that any dirt or debris in the system is flushed out before it enters the injector, preventing clogging and sticking.
Fourth, when connecting the high-pressure tubing to the fuel pump and injector, avoid using lead wire or asbestos for sealing. These materials can easily break apart under pressure and get lodged inside the fuel injector, causing the needle to stick. Instead, use a thin copper sheet cut to the correct size, punch a hole in the center, and place it between the high-pressure hose and the connector. This method is safer and more effective.
Lastly, some diesel engines come with a filter at the outlet of the high-pressure fuel line. This filter plays an important role in keeping the fuel clean. It's a mistake to remove the filter while installing the fuel injector. Not only should the filter remain in place during installation, but it should also be cleaned regularly to ensure optimal performance and prevent contamination.
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