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Guangzhou Baijiahui Industry & Trade Co., Ltd stocks a variety of fuel injectors, automotive sensors, ignition coils, spark plugs, power window switches, idle speed control valves, VVT timing valves, clock spring wires, and more. With over 10,000 different part numbers, we strive to be the first choice for all your diesel injection needs.

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What is Common Rail Injector?

Common rail direct fuel injection is a direct fuel injection system built around a high-pressure (over 2,000 bar or 200 MPa or 29,000 psi) fuel rail feeding solenoid valves, as opposed to a low-pressure fuel pump feeding unit injectors (or pump nozzles). High-pressure injection delivers power and fuel consumption benefits over earlier lower pressure fuel injection, by injecting fuel as a larger number of smaller droplets, giving a much higher ratio of surface area to volume. This provides improved vaporization from the surface of the fuel droplets, and so more efficient combining of atmospheric oxygen with vaporized fuel delivering more complete combustion.

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Working Principle of Common Rail Injector

Initial State

When the injector solenoid valve is not triggered, the injector is closed, the drain hole is also closed, and the small spring presses the armature ball valve against the orifice to form a common rail high pressure in the valve control chamber. Similarly, a common rail high pressure is also formed in the injector, and the common rail pressure balances the pressure of the control plunger section and the pressure of the nozzle spring with the opening force of the high pressure fuel on the tapered surface of the needle valve, so that the needle valve remains closed.

Fuel Injection Start Status

When the solenoid valve is triggered, the armature opens the drain hole, the fuel flows from the valve control chamber to the upper cavity, and returns from the cavity to the oil tank through the oil return pipe, so that the control chamber pressure is lowered; the control chamber pressure is reduced, and the pressure is reduced. The force acting on the control plunger, at which point the nozzle needle is opened and the injector begins to inject oil.

End Of Injection

Once the solenoid valve is powered off, the force of the small spring will not be triggered, and the solenoid valve will be pressed down. The ball valve will close the drain hole. After the drain hole is closed, the fuel will enter the control chamber from the oil inlet hole to establish the oil pressure. This high pressure is controlled. On the cross section of the plunger, the rail pressure plus the spring force is greater than the pressure on the conical surface of the needle valve, causing the diesel nozzle needle to close.

Advantages of Common Rail Injector

Lower Emissions: One of the reasons that common rail diesel engines were invented by vehicle manufacturers was because the government created stricter regulations on carbon emissions. Remember when big diesel trucks used to release a lot of black smoke into the air? You hardly see that anymore because the common rail diesel engine is designed to reduce those emissions. This is better for the environment and is one step closer to fighting global warming.

More Power: Studies have shown that vehicles with a common rail diesel engine will produce 25 per cent more power than a traditional diesel engine. This means the overall performance of the diesel engine will be improved.

Less Noise: Direct fuel injection systems were known for being noisy while driving. The common rail will reduce a lot of the noise that you might remember hearing. This makes it a more pleasant driving experience for you and those around you on the road.

Fewer Vibrations: There used to be a lot of vibrations felt in traditional direct fuel diesel engines. Now those vibrations have been reduced with the common rail direct injection system.

Better Mileage: Since the common rail diesel engine provides more power, that means you will get better mileage on your fuel. As a result, your fuel economy will be better as well. This means less money spent on fuel when you're on the road.

Types of Common Rail Injector

Electromagnetic Type

●Simplified operation: When activated by the Diesel ECM, the Electromagnetic solenoid on top of the injector allows the internal high-pressure hydraulics to lift the needle off its seat and injection takes place. As soon as the solenoid is de-activated, the internal hydraulic pressure forces the needle on its seat and injection is terminated. Multiple injections may occur in one cylinder firing cycle to control the explosive combustion for emission and noise reduction.

●The fuel rail and internal injector hydraulic fuel pressure varies dramatically depending on driving and operating conditions which requires the ECM to alter injector opening times (please be aware of safety requirements due to high fuel pressures).

●High operating Voltages and current are required to initially start injection. Typically, "Opening Voltage" from 60 - 100V.

Piezoelectric type

●Simplified operation: The internal construction of the Piezo injector varies with the Electromagnetic type. A stack of internal semiconductors expand when activated (Instead of solenoid) which results in much quicker injector opening times. This allow for an increased number of pre and post main injection operations for an individual cylinder combustion cycle which results in a smoother, cleaner and quieter engine. Most manufactures are now currently utilising this type of injector on new vehicles.

●The fuel rail pressure / injector operating pressure is generally greater on this system which allows for finer fuel spray.

●Typical operating voltages and current on most systems may be in the range of 100 - 400V and minus 20 to +20 Amps.
Reversing injector polarity by the ECM may be required on many systems to retract the semiconductors to rapidly terminate injection. Warning - Not recommended to remove injector harness from injector when the engine is operating as the injector "may" continue to inject fuel and cause engine damage.

Method for Forming a Common Rail Injector

Inserting an electric coil assembly within a magnetic core and positioning both within a separable mold wherein said electric coil assembly includes a wire wound on a bobbin having a pair of electrical contacts extending therefrom.

Inserting a first removable pin into an opening concentrically formed in both said magnetic core and said coil assembly.

Inserting a second removable pin to encapsulate said pair of electrical contacts.

Injecting plastic into said mold for hermetically sealing said coil assembly within said magnetic core and also forming a fuel injector housing surrounding said coil assembly and said magnetic core.

Removing said first pin to define an electrical connection for said pair of electrical contacts which is external to said housing and sealed from said fuel passageway.

Removing said separable mold to define an integrally formed fuel injector housing with a fuel passageway, magnetic core, and hermetically sealed electric coil assembly positioned therein.

Inserting an armature comprised of a magnetic permeable material into said fuel passageway; and coupling a needle and seat valve to said armature and to said fuel passageway for controlling fuel flow.

Methods for Troubleshooting Common Rail Injectors

During the working process of the fuel injector, various faults and phenomena will appear. So what are the ideas and methods for troubleshooting the common faults of the fuel injector? Let us take a look together:

The Nozzle is Blocked
Prevention method: On the one hand, the fuel entering the injector must be strictly filtered; on the other hand, by improving the combustion, preventing the nozzle hole from being blocked due to excessive carbon deposits.

The Nozzle Drips Oil
Remedy: Remove the fuel injector, check whether the movement of the needle valve is flexible and whether the sealing of the seat surface is good, and then carry out careful cleaning and research or replace it with a new fuel injector assembly.

Injector Corrosion and Carbon Deposits at the End
Remedy: Remove the nozzle device, and remove the carbon deposits on the nozzle by mechanical or weakly corrosive methods. It is important to remove the carbon deposits inside the nozzle hole, but the sealing seat surface must be protected from damage. In order to prevent the wire used for cleaning from breaking in the hole, the wire must be installed in the chuck, and the length of the wire exposed to the nozzle hole should not exceed 2 mm.

The Needle Valve is Stuck
Remedy: Remove the fuel injector, take out the fuel injector assembly, and pull out the needle valve with a tool. If it is not easy to pull out, first put the fuel injector assembly in diesel and heat it for about 20 minutes before taking it out. When removing, pad the tail of the needle valve with copper skin, use pliers to clamp the tail while rotating and pull it out. After pulling it out, put it in the cleaning solution for cleaning, and then reload it. If it is dirt intruding, it will become flexible after cleaning. If it is due to the geometry of the mating part that affects the flexibility, a small amount of grinding paste should be added, and light grinding should be carried out. After grinding, cleaning should be carried out.

How To Remove and Replace a Common Rail Injector

Step 1

By removing the cover, we can see the common rail system. We're going to start by removing the injector pipe, When you are doing the pipes make sure that any exposed parts are capped because of the risk of contamination. Next, remove the back linkage, on this particular application you're going to have to remove the globe connector using a pair of pliers. Next, remove the electrical connection. This now leaves the retaining clamp holding the injector. Finally, withdraw the injector from the seat.

Step 2

Fit a repaired injector. Make sure that the injector is the correct part number, all injectors are vacuum sealed to ensure cleanliness. Prior to fitting the injector, you need to note down the correction code.

Step 3

To refit the injector you are going to remove the protective cap from the nozzle and slide the injector carefully into its place. Now, refit the retaining clamp. Next, refit the electrical connector, the back leakage, and the glow plug.

Step 4

Now that we've fitted the injector, we need to refit the high-pressure fuel pipe. Using the correct tooling you're going to apply the correct torque to the pipe. The physical repair has now been completed.

Step 5

Enter the code so that the control unit of the vehicle, can tally up with the injector we've just fitted.

Step 6

Lastly, confirm your repair by starting the vehicle up. Now that we've entered the code the control unit and the injector should be tied up.

Frequently Asked Questions

Q: What is common rail injection?

A: The term "common rail" refers to the fact that all of the fuel injectors are supplied by a common fuel rail which is nothing more than a pressure accumulator where the fuel is stored at high pressure. This accumulator supplies multiple fuel injectors with high-pressure fuel.

Q: What is the common rail injector operation?

A: The rail serves as a fuel accumulator to maintain a relatively constant pressure at all fueling rates used by the engine. From the rail, the fuel is supplied to the injectors via high pressure pipes. The ECU generates current pulses which energize a solenoid valve in each injector in sequence.

Q: What is the difference between common rail and direct injection?

A: A common rail is one of the most important components in a diesel and gasoline direct injection system. The main difference between a direct and a standard injection is the delivery of fuel and the way how this one mixes with incoming air.

Q: Why do common rail injectors need coding?

A: Coding is fundamentally the most important aspect of CR injector calibration because new and reconditioned injectors alike need to be re-aligned to deliver the correct quantity of fuel at the right time during the combustion stroke, to meet stringent emissions standards.

Q: Is common rail only for diesel?

A: Common rail direct fuel injection is a direct fuel injection system for petrol and diesel engines. On diesel engines, it features a high-pressure (2,000 BAR - 29,000 PSI) fuel rail feeding individual solenoid valves, as opposed to a low-pressure fuel pump feeding unit injectors or pump nozzles.

Q: Why do common rail injectors fail?

A: Modern common rail systems generally have a long lifespan. However, they're still susceptible to issues. While many things can cause breakdowns, the most likely cause of premature failure is fuel contamination. Fuel contamination occurs when debris in the fuel gets past the filtration, destroying the sealing surfaces.

Q: What is the pressure of the common rail injector?

A: How Diesel Common Rail Fuel Injection Works. It features a high pressure pump delivering over 1,000 bar or 100 MPa or 15,000 psi of fuel pressure to the common rail assembly, which delivers the constant high pressure fuel to each injector.

Q: What fails in common rail injectors?

A: Diesel common rail injectors can fail due to a variety of reasons, including: Contaminated fuel: Impurities in the fuel can cause damage to the injectors. Wear and tear: Over time, the internal components of the injectors can wear out, leading to failure. Overheating: Excessive heat can cause the injectors to fail.

Q: What are the injection phases of the common rail?

A: The main injection phase delivers the fuel, a pre- injection phase reduces the load on the crankshaft drive gear, and a post-injection phase reduces particulate emissions. This enables both fuel consumption and emissions to be reduced.

Q: What is the difference between ejector and injector?

A: Ejectors are considered an alternative to mechanical vacuum pumps because no power source is required other than the motive gas and they are very reliable because there are no moving parts. Injectors are used to increase the temperature of a liquid.

Q: What are the 2 types of injector used in a common rail diesel engine?

A: These injectors may be categorised into two general types.
Electromagnetic CRD injectors.
Piezoelectric CRD injectors.

Q: What is the main difference between a mechanically operated injector and a common rail injector?

A: Unlike common rail systems, mechanical injection systems don't use electronically-controlled valves; instead, they rely on the movement of the engine pistons to provide accurate ignition timing.

Q: What happens if injectors are not coded?

A: Overheating: If the injectors are not coded correctly, the engine may not get enough fuel, causing the engine to overheat. Engine Misfire: If the injectors are not programmed correctly, they may not deliver the correct amount of fuel at the correct time, causing the engine to misfire.

Q: Can common rail injectors be cleaned?

A: Diesel Injector Cleaner is a powerful multi-functional chemical package formulated to clean all diesel engines including common rail injectors and combustion chamber deposits fast. It improves fuel system efficiency and economy, reduces black exhaust smoke and makes cold starting easier.

Q: How long do common rail injectors last?

A: The life expectancy of a good quality diesel fuel injector is around 150,000 kilometres. They should be checked out by a professional at around this time.

Q: Can common rail injectors be repaired?

A: All common rail injector repair assemblies are done by laying out and thoroughly checking each part of the injector using Bosch software. This permits us to establish exactly the correct shims in order for every rebuilt injector to meet exact factory specifications.

Q: Which is better CRDI or TDI?

A: CRDI has a high pressure pump inject the fuel so it do not require a turbocharger, but TDI uses turbocharger from exhaust to increase the engine power and efficiency. 2. If we compare the efficiency orbit Technologies, CRDI seems to win.

Q: How do you diagnose faulty common rail injectors?

A: Check engine light: a fault in any one of the injectors or fuel system, can trigger the engine management light to come on. Engine knock: an audible knocking sound from the engine bay, indicates that the timing of the combustion process is off, causing premature detonations.

Q: What are the symptoms and reasons for the common injector failures?

A: Common problems include stalling after you have pressed the accelerator, struggling to accelerate and poor fuel economy. Most of these problems occur due to inadequate air to fuel ratio. Also, any delay could lead to overheating and the engine could stall.

Q: Is common rail injection better?

A: Noise, vibration and harshness (NVH) are improved with CRDi as a result of the timing flexibility. Your engine sounds quieter and has a better quality of sound. It also runs smoother.

Q: What is the advantage of direct injector?

A: Better fuel economy and lower emissions due to better fuel atomization. Works well with E85 flex fuel, which is a high-level combination of ethanol and gasoline. Reduced turbo lag on turbocharged engines. Fuel acts as a coolant, allowing for higher compression ratios.

Q: Why is direct injection better than port injection?

A: Direct injection is very precise, and allows for great emissions benefits. Port injection is less efficient but allows for more fuel to be sprayed into a cylinder (not to mention it cleans the valves) to increase power. Using both in conjunction is amazing for both maximum economy and maximum performance.

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