and Injector Fault Identification ... . ... PICTURE OF CONTAMINATION CAUSES OF FAILURE : PREVENTION...

Pump and Injector Fault IdentificationCause, Effect and Prevention

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PRODUCT NUMBERS PICTURE OF CONTAMINATION CAUSES OF FAILURE PREVENTION

ACTION

DELPHI NON COMMON RAIL PUMP

1) Internal partscontaminated2) Inadequate filtration,poor filter quality3) Filter service lifeexceeded4) Poor fuel quality

1) OE filtersshould be used2) Maintainrecommendedservice intervals3) Correct fuelgrade to be used(EN590)

BOSCH VP FUEL PUMP

1) Internal partscontaminated2) Inadequate filtration,poor filter quality3) Filter service lifeexceeded4) Poor fuel quality

1) OE filtersshould be used 2) Maintainrecommendedservice intervals3) Correct fuelgrade to be used(EN590)4) Cleanlinessduring fitment ofproducts

BOSCH DRV VALVE

1) Drive valve on Boschfuel pump corroded2) Poor fuel quality3) Water contamination4) Inadequate filtration,poor filter quality

1) OE filtersshould be used2) Maintainrecommendedservice intervals3) Correct fuelgrade to be used(EN590)

BOSCH COMMON RAIL FUEL PUMP CP3

1) Fuel internalparts corroded andcontaminated2) Inadequate filtration,poor filter quality3) Filter service lifeexceeded4) Water in fuel

1) OE filtersshould be used2) Maintainrecommendedservice intervals3) Correct fuelgrade to be used(EN590)

PRODUCT NUMBERS PICTURE OF CONTAMINATION CAUSES OF FAILURE PREVENTION

ACTION

DENSO COMMON RAIL PUMP

1) Fuel internal partscontaminated2) Inadequate filtration,poor filter quality3) Filter service lifeexceeded

1) OE filtersshould be used2) Maintainrecommendedservice intervals3) Correct fuelgrade to be used(EN590)

BOSCH COMMON RAIL PUMP

1) M-prop valve onBosch fuel pumpcorroded2) Poor fuel quality3) Water contamination4) Inadequate filtration,poor filter quality

1) OE filtersshould be used 2) Maintainrecommendedservice intervals3) Correct fuelgrade to be used(EN590)

BOSCH NOZZLE 1) Injector nozzle2) Inadequate filtration,poor filter quality3) Filter service lifeexceeded4) Debris introducedduring fitment

1) OE filtersshould be used 2) Maintainrecommendedservice intervals3) Correct fuelgrade to be used(EN590)4) Cleanlinessduring fitment ofproducts

BOSCH VP FUEL SOLENOID

1) Internal partscontaminated2) Inadequate filtration,poor filter quality3) Filter service lifeexceeded4) Poor fuel quality

1) OE filtersshould be used 2) Maintainrecommendedservice intervals3) Correct fuelgrade to be used(EN590)4) Cleanlinessduring fitment ofproducts

PRODUCT NUMBERS PICTURE OF CONTAMINATION CAUSES OF FAILURE PREVENTION

ACTION

DELPHI COMMON RAIL INJECTORS

1) Contamination fromtechnician’s workingpractice2) Cleanliness inworking environment3) High pressure pipereplacement not carriedout4) Inadequate filtrationof fuel5) Abrasive fuel beenused6) Fuel pump failure7) No injection due tovalve seized ( 0.3-0.4Microns) contamination

1) Good workingpractice carriedout2) OE fuel filtersto be used3) Correct fuelgrade to be used(EN590)4) Replace allhigh pressurepipes to injectorsif injectors areremoved

DELPHI COMMON RAIL INJECTORS

1) Contamination fromtechnician’s workingpractice2) Cleanliness inworking environment3) High pressure pipereplacement not carriedout4) Inadequate filtrationof fuel5) Abrasive fuel beenused6) Fuel pump failure7) No injection due tovalve seized ( 0.3-0.4Microns) contamination

1) Good workingpractice carriedout2) OE fuel filtersto be used3) Correct fuelgrade to be used(EN590)4) Replace allhigh pressurepipes to injectorsif injectors areremoved

BOSCH INJECTORS 1) Internal partscontaminated2) Inadequate filtration,poor filter quality3) Filter service lifeexceeded

1) OE filters to beused2) Serviceintervals need tobe maintained3) Correct fuelgrade to be used(EN590)

BOSCH INJECTORS 1) Erosion wear on valvepiece ball seat2) Poor abrasive fuel(particles)3) Poor and inadequatefiltration

1) OE filters to beused2) Serviceintervals need tobe maintained3) Correct fuelgrade to be used(EN590)

BOSCH INJECTORS / VDO INJECTORS

1) Water in fuel2) Poor fuel3) Inadequate filtration,poor filter quality4) Filter service lifeexceeded

1) OE filters to beused2) Serviceintervals need tobe maintained3) Correct fuelgrade to be used(EN590)

PRODUCT NUMBERS PICTURE OF CONTAMINATION CAUSES OF FAILURE PREVENTION

ACTION

BOSCH INJECTORS / VDO INJECTORS

1) Inlet port and edgefilter corroded2) Water in fuel3) Poor fuel4) Inadequate filtration,poor filter quality5) Filter service lifeexceeded

1) OE filters to beused2) Serviceintervals need tobe maintained3) Correct fuelgrade to be used(EN590)

BOSCH INJECTORS 1) Internal partscontaminated2) Inadequate filtration,poor filter quality3) Filter service lifeexceeded4) Debris introducedduring fitment

1) OE filters to beused 2) Serviceintervals need tobe maintained3) Correct fuelgrade to be used(EN590)4) Cleanlinessduring fitment ofproducts

DELPHI INJECTOR 1) Internal partscontaminated2) Inadequate filtration,poor filter quality3) Filter service lifeexceeded4) Debris introducedduring fitment5) Water in fuel

1) OE filters to beused 2) Serviceintervals need tobe maintained3) Correct fuelgrade to be used(EN590)4) Cleanlinessduring fitment ofproducts

BOSCH / DELPHI / VDO / DENSO INJECTOR NOZZLES

1) Injector nozzles2) Thermal overload3) Diesel tuning4) Incorrect or non-approved additives infuel5) Engine oil inintake system, seals6) Oil thinning

1) OE filters to beused 2) Serviceintervals need tobe maintained3) Correct fuelgrade to be used(EN590) 4) Correct gradeof engine oil to beused5) Aftermarketperformanceenhancingequipment not tobe used