COMMON RAIL INJECTOR
to rust and corrosion problems that can cause sticking internals, meaning poor efficiency and continued running problems. Simple things like regular fuel filter changes, adding a quality fuel treatment or even just buying fuel from the right place can really go a long way toward overall injector longevity. On some models, cracking of the injector body can also be an issue when running extreme rail pressures.
After receiving a set of core injectors to be rebuilt, there are quite a few steps followed to ensure that a “like new” topquality product is assembled and resold. Replacing the common failure items, cleaning everything in an ultrasonic cleaner, measuring tolerances, flow bench testing and perfectly matched injection nozzles are all used to ensure you receive a completed set of injectors that can maximize efficiency, performance and drivability. While a basic remanufacture to stock specifications is most common, Industrial Injection can also rebuild an injector to exceed factory performance with their extrude honed injection nozzles and other internal modifications. Using a state-of-the-art extrude hone machine, technicians can run brand new OEM Bosch injection nozzles through the honing process to enlarge the holes in the nozzle to improve fuel flow. There’s everything from a mild 50-hp nozzle that can improve a truck’s mileage, power and street-ablilty without putting undo stress on the powertrain to all-out, competition-only, 500+ horsepower nozzles for those wanting to make a statement on the sled pull or dragstrip. Over the course of the last year, with the help of a new in-house engine dyno, Industrial Injection has pushed multiple Cummins past 2,500 hp using their cutting-edge common rail Cobra injectors.
Here you can see how effective the ultrasonic cleaner can be in bringing this internal pintle back to near-perfect condition. The pintle inside the injector is what moves up and down to control the injection event. As fuel rail pressure builds and the injector solenoid is signaled to move the armature, the pintle will move and allow fuel to run to the nozzle and be injected into the cylinders.Industrial Injection’s common rail injector specialist Coy Larsen installs a completed set of 5.9L injectors into the test bench to check them for proper function and running condition. The flow bench is electronically controlled and uses a factory CP3 injection pump to give as close to an “in the truck” running test as possible. The test bench can check each injector and find any issues before they are sent out. If any injector is found to be outside the OEM specification, or just not balanced well with the rest of the set, the technician can remove it from the bench, adjust and re-test as needed.
With the armature and other internals removed from the bad injector, you can see that the corrosion just gets worse the further into it you get. Rust and pitting all along the inside of the injector and threads tell the story. Proper fuel filter changes, good clean fuel, fuel treatment and even the addition of aftermarket fuel filtration systems are all great ways to combat these sorts of issues.