LEARNING ACTIVITY WEEK FOUR

Learning activity: 'Repair and testing of the injection system'

Names: Esteven Alejandro Alvarez Rios
Email: alejo39500@[Link]

Chosen option to develop the activity1: Option One: (Text) X Option Two:
(Tools)
INSTRUCTIONS:
Description: For the execution of the activity, the participant has two options to choose from.
choose one since any of them demonstrates the completion of the activity:

Option One: Summary Text

Instructions: Address the course support documents and study the supporting materials.
Chapter nine. Based on this, develop a step-by-step guide for the calibration of an injector.
Product to be delivered: Format“"Activity_Learning_Week_Four_BLM.doc" filled out.

Option two: List of tools.

Instructions: Create a list of tools necessary to carry out the replacement of components such as
air filters, diesel, oil, as well as the necessary equipment for diagnosis and operation of the
injectors and pump of the Mechanical Injection system, and to carry out the emission entry tests
contaminants of the engine exhaust system.
Product to be delivered: Format“"Activity_learning_Week_Four_BLM.doc" filled out.

DEVELOPMENT OF THE ACTIVITY:

SYMPTOMS OF MALFUNCTION The inspection of the injectors should be done when it is detected
a deficient functioning of them. The symptoms of injector malfunction are:
the emission of black smoke from the exhaust, lack of engine power, excessive overheating, increase of
fuel consumption and engine knocking noise. The faulty injector can be located by doing the
test disconnecting the fuel supply line while the engine is running. In
These conditions are observed if the exhaust smoke is no longer black, the knocking stops, etc., in which case,
the injector that has been disconnected is the defective one. It should be noted that if we disconnect an injector the
the motor has to drop in revolutions, this demonstrates that the injector is indeed working. CALIBRATION OF
INJECTORS. 1. To perform the injector calibration, it can be done using two methods. 1 See guide
Didactics Option One: Summary Text Instructions: Address the course support documents and carry out the study
from the support materials for chapter nine. Based on this, develop a step-by-step guide for the calibration of a
Injector. Product to be delivered: Format "Actividad_aprendizaje_Semana_Cuatro_BLM.doc" filled out.
a. WITH ADJUSTING SCREW: It consists of a screw that, when tightened, makes contact with the spring.
pressing it against the shaft that pushes the needle against its seat, which causes the pressure to increase
flammable upon exiting through the holes. When loosening them, the force of the spring against the shaft gives way, decreasing the
fuel pressure when exiting, and a lock nut responsible for securing the screw so that it does not become unbalanced
Injector.b. WITH CALIBRATED WASHERS. To perform the calibration with calibrated washers. It must be
to have a good assortment of these in different thickness measurements. They usually come in hundredths of
millimeter and in thousandths of an inch. With this method, the caliper is a bit expensive because they must be placed
washers in the injector must be checked every time they are changed. Placing washers increases the
Pressure dropping, decreases. INJECTOR CALIBRATION 1. Install the injector on the injector tester and eliminate
the air loosening the high-pressure tube nut. 2. Pump slowly (once per second) and observe the
Manometer. 3. Read the pressure on the manometer just when the injector sprays and adjust it if necessary to the
recommended injection pressure by the manufacturer in the service [Link] TEST1. Keep the
pressure (between 120 and 250 psi) below the injection pressure. 2. Check for any dripping at the tip
sprayer or around the body. 3. If there is dripping, clean it and give it a settling, if the dripping continues
replace the nozzle. SPRAY TEST 1. Move the pumping lever 4 to 6 times.
second or more. 2. Observe the spraying. 3. If the spraying is not correct, clean the nozzle. If it does not improve
I changed the nozzle. PRESSURE IDIOT
By operating the pump lever at an approximate cadence of 60 strokes per minute, it
you will observe the maximum reading reached on the manometer, which corresponds to the calibration pressure of the injector, the
what must be stipulated by the manufacturer. If the opening pressure is higher than prescribed, it is a symptom of
that the injector needle is "stuck", or due to a partial obstruction of the nozzle, or to an incorrect precharge
from the pressure spring. If the pressure is below the prescribed level, which usually happens when the injector has
operated more than 50,000 km, this is usually due to lack of tension in the pressure spring or its breakage.
In any case, the injector must be disassembled and cleaned, and it must be calibrated.
correct pressure. This taring operation is performed by tightening or loosening the adjustment screw (3, of the figure
inferior) or inserting calibrated spacers (washers) between the spring and the casing, depending on the case. LEAK OF
RETURN By operating the control lever of the pump of the tester until achieving a pressure in the
injector of approximately 10 bar below the set pressure, the fuel shutoff valve will close
that the tester is equipped. Under these conditions, a slow drop of the clock hand must be observed
comparator, indicating the return leakage level. An injector is generally considered correct when
return leak level, if the pressure is maintained above 50 bar for more than six seconds, starting from a
pressure of 100 bar. The return leak indicates the amount of fuel that exits between the valve rod.
needle and the body of the nozzle, towards the return. This leak must exist in a certain proportion, to lubricate these
components. If it is small, it indicates a slight clearance between the needle and the nozzle. If the leak is excessive, it indicates
greater clearance than necessary and the nozzle must be replaced or repaired. CHECKING Regarding
the verification of components, the joining faces of the nozzle support and the holder must be inspected
injector. If there are scratches, corrosion, or deformations, they must be replaced. They will also be examined.
decoupling surfaces of the injector needle and the nozzle. A bluish tone on these surfaces indicates that
they have operated at excessive temperatures, which can cause the material to temper, for which
both pieces must be replaced. The needle seat must have a good matte finish on the
contact areas, without step indicating excessive wear. If scratches are found in these
areas, these components must be replaced, taking into account the fit between the needle and its nozzle.
It will also be checked that the needle slides easily inside the nozzle, without jamming or sticking.
clearances. With the nozzle placed in a vertical position (lower figure), the needle must fall to the bottom of the seat.
its own weight. By pressing it lightly with the hand against its seat, when inverting the position of the nozzle,
the needle must remain above its seat, if both are soaked with diesel and, when lightly tapped with
the fingers must fall freely. If this does not happen, cleaning must be done again and
descaling and, if this is not enough, the assembly will be replaced. CLEANING VERIFICATION OF
INJECTORS If we know that the injector has some type of problem in its operation, it should be proceeded to the
disassembly of it to check the condition of its components and carry out the appropriate cleaning of them,
which is done with brass rods with sharp tips and wire brushes, also made of brass. With these tools
The external and internal surfaces of the nozzle and the needle are cleaned to remove carbon particles.
deposited in them, without causing scratches that would later hinder functionality. The incrustations
Strong in hard-to-reach places, such as the nozzle drill, can be softened by immersing it in water.
mixed with caustic soda and detergent. It should then be cleaned and dried, before being immersed in
continuation in diesel until the moment of assembly. PRESSURE MEASURES The injection pressure is
important as it requires a value that lifts the valve overcoming a spring. When it starts the
Injection, the fuel must find resistance in the holes to keep the valve open and achieve
atomization. When the engine speed is low, the fuel also has a low speed, which leads to
place where the pressure tends to fall so the valve descends, unclogging the output and raising the pressure.
This is how a needle oscillation can be repeated with its characteristic click. (Sound). The pressure should not be exceeded.
above normal due to excessive atomization, impairing the mixture and penetration. The
Manometers of the problems let's see some equivalences: 1 K/cm2 = 14.2 lb./in2 = 1.033 Kg./cm2 = 1 ATM
= 760 mm. mercury column. 1 ATM = 14.7 lb./in² 1 ATM = 10.033 m. water column. 1 BAR = 0.98
ATM.
1 KPa = 10 Newton/m2 1 SAR = 100 KPa. 1 BAR = 1Q Pa.