NW Diesel Service - Broken Injector Connector after faulty fuel injection repair

Why You Need to Use the Right Tools for Fuel Injection Repair

We need more than just our technical know-how for a successful repair. To provide the best service possible, we also need the right tools. When manufacturers design parts nowadays, they focus on ease of assembly or maximizing fuel economy. Often, serviceability is an afterthought. More and more, technicians need specific tools to remove or replace specific parts.

Specific Tools in the Fuel Injection Repair Industry

Leading repair shops should be willing to invest in the correct tools and equipment for each repair. Island Diesel Injection, our sister service shop in Nanaimo, recently had to test a set of Cummins ISL common rail injectors. In order to successfully test these injectors, a special adaptor block had to be purchased at a much higher cost than the revenue earned from testing one set of injectors. Thinking of being better equipped for the future customers, they took on this expenditure and consider it again.

Continually investing in new tools and technologies is one of many ways the Diesel Done Right family strives to remain at the top of our industry.

Specific Tools for Repair Shops and Mechanics

NW Diesel Service - Broken Injector Connector NW Diesel Service - Injector Connector

This next example is geared toward general repair shops and backyard mechanics. One of our technicians had to replace a broken electrical connector for a Siemens G2.8 injector, shown above. A new connector is also shown for comparison. These injectors are found in the Ford 6.0 and 4.5 litre Powerstroke engines, as well as Navistar VT365, VT275 and Maxxforce 5. These electrical connectors fit through machined holes in the engine rocker arm carriers. In this instance, the connector was damaged during removal, most likely due to the use of a hammer.

The proper way to remove an electrical connector is to disengage the locking tabs on the outside of the connector with an Injector Connector Removal Tool. This tool fits around the outside of the connector and gently unlocks the locking tabs by pushing them inward. This allows the connector to be pushed through the rocker carrier. We happen to carry the Alliant Power AP0017 G2.8 Injector Connector Removal Tool, which is specifically designed for this purpose.

NW Diesel Service - Alliant Power - Injector Connector Removal Tool

Although the damage to the connector in this example might not look extensive, our technician had to spend a fair amount of time cleaning up the rough edge with a file before the injector could be plugged into our HI2000 hydraulic injector test bench.

It is also worth noting that there is an O-ring around the outside of the connector that seals it against the rocker carrier. If the connector cracks, engine oil can leak out into the engine valley. This means more frequent oil top offs, an increased risk of contaminating the environment, or even creating a potential fire hazard if the oil drips beneath the intake manifold and accumulates by the EGR cooler.

Today’s diesel vehicles are more sophisticated than ever, a trend that is sure to continue. For expert vehicle service from expert technicians equipped with the right tools, the correct and most up to date service information, and the correct parts, come see us at NW Diesel Service.

Diesel, Done Right.