Injector Extraction & Replacement Service

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Basically, the purpose of a fuel injector is to spray the fuel in atomized or mist form so that it burns completely & uniformly. Fuel Injection Pump (FIP) supplies pressurized diesel fuel thru’ high-pressure lines to each injector's inlet port.  

The Diesel engines and especially the common-rail injection systems are notorious for the build up an excess of carbon deposits and rust around the injector. These carbon residues are result of the process called carbonization - coking. When the engine is turned off, the coolant system stops circulating  coolant and as consequence of this causes the temperature to rise. The residual fuel tends to be evaporated and is produced the deposition of carbon residues in the adjacent area of combustion chamber. With certain frequency and as a consequence of the cinder accumulation in the housings, the injectors and/or glow plugs are blocked, due to the fusion with the walls of the cylinder head, and it is practically impossible to accomplish the extraction by normal procedures...

In other occasions and due to incorrect seat of the injector, carbon residues are accumulated around the injector that can derive in the blockade in the housing of the cylinder head. What is same occurs if the seat of the glow plug is defective. The components also they can be blocked due to the effects of water ingress by splits, leading to the fusing with the aluminium cylinder head.

 
When the extraction is accomplished can be caused damages in the cylinder head and in occasions is required to replace the cylinder head. In any case, in these circumstances the extraction of the components requires increased repair times. 

To solve this problem, in  ZEEKKA DIESEL we the diesel experts approaches it with advance design removal tools (mechanical and hydraulic systems) to remove the stuck or seized components with a total reliability. Our experienced technicians handles it to avoid damages in the cylinder head during the extraction. In most cases to accomplish the extraction is not required to remove the cylinder head from the engine.

Advantages
The use of the Removal Tools resulting in substantial benefits:

• Extraction of the injectors and/or glow plugs with a total reliability
• Decrease of the operative costs:
  • Remove the cylinder head is not required to accomplish the extraction
  • Damages in the cylinder head are not produced
  • Decreasing labor costs
• Very quick payback of the tools
• Costs saving to the customer
• Satisfaction of the customer

Practical Notes

1. Each time the injectors are removed, it should be proceed to clean the housings in the cylinder head, rebuild the injector seat and replace the sealing copper washer.
   If the injector seat is defective, the problem is not solved replacing only the copper washer.
   The reason for this is that the seat in the cylinder head has been eroded by the escaping combustion gases, resulting in damage to the seat.
2. To remove the seized glow plugs, we have found cases in which is proceeded to drill the glow plug directly..., without using an adequate center system..., these procedures are inappropriate and result in irreparable damages in the walls of the cylinder head.
   To remove the seized glow plugs and injectors are required tools that are perfectly adapted to the geometry of the cylinder head.
3. The same as for the injectors, each time the glow plugs are removed, it should be proceed to clean the housings in the cylinder head and check the perfect seat.