G3S103 diesel injection nozzle is one of the main working parts of the fuel injector. It is responsible for injecting fuel into the combustion chamber and is a key component to achieve precise injection, oil mist formation, etc.
G3S103 Diesel Injection Nozzle is one of core components of fuel injector, also one of parts with the highest damage rate.
Causes of Damage to G3S103 Diesel Injection Nozzle
- Fuel injection nozzlefailure caused by impurities (water, lead, aluminum powder, iron powder, sulfide) in fuel exceeding standard requirements.
- The nozzle is normally worn due to long time working under high temperature
- Nozzle needle wear leads to oil hole blockage, insufficient fuel injection injector cannot work properly.
- Nozzle needle wear leads to oil hole blockage, insufficient fuel injection injector can’t work properly.
- The wear of the nozzle leads to the increase of fuel quantity, resulting in black smoke of the vehicle, and the fuel injector can’t work properly when it is serious.
- If the nozzle needle can’t move smoothly stuck may cause serious damage to the Diesel Injection Nozzle
- The rusting of the nozzle spring leads to spring fracture and black smoke from the vehicle.
- The opening pressure of the nozzle decreases, and the oil quantity of the injector increases, leading to black smoke of the vehicle, and the injector can’t work properly when it is serious.
- Oil-nozzle needle valve lift adjustment gasket wear oil-nozzle needle valve stroke becomes larger, the fuel injector oil quantity becomes larger, resulting in black smoke of vehicles, resulting in the fuel injector can’t work properly when serious.
- The cracking of the nozzle cap is caused by high intensity work under high temperature.
G3S103 Diesel Injection Nozzle’s Installation
（1）Tightening torque of injection nozzle
The torque lever and tightening moment specified in the injector maintenance manual must be
Installed when the injection nozzle is installed. (50Nm)
The tightening torque of the nozzle cap must be installed in accordance with the tightening torque specified in the injector maintenance manual.
G3S103 Diesel Injection Nozzle Testing After Maintenance
- After installation, it needs to be tested on the test bench.
The correct injector type should be selected for testing
- The test results need to be ensured that the following items are within the standard data range of the test stand.
LEAK TEST: Test whether sealing test is up to standard or not
In this step, no injector collector should be installed at the nozzle during the test so as to observe whether the nozzle is dripping oil, meanwhile observe that all joints are no oil leaking.
The static oil return of the test should not exceed 8mm2/H, otherwise, you need to check whether the high-pressure sealing ring, valve assembly, and stroke parameters of the injector are within the standard range.
VL: Test whether full load oil (main injection, high speed) is up to standard or not
This step needs to be combined with vehicle driving conditions, such as power, fuel consumption and smoke as well as the maintenance of the engine, if there is situation of insufficient power, fuel consumption is high, thick black smoke and irregularly maintenance of the engine, the engine needs to be maintained according to the maintenance handbook at very first time.
Each of injector part needs to be adjusted and checked if there is any damage according to above situations to ensure the injector is normal. After make sure the injector works normal, you need to reduce the armature stroke if too much oil injection, and increase the armature stroke if too little oil injection.
The error of each injector should be controlled in 6mm3/HH when adjusting.
TL\EM: Test whether the torque point, emission point, exhaust limit, fuel supply reach standard or not
Through this test, it is detected that when the oil injection is too little, the engine’s acceleration is slow, vice versa, when the oil injection is too much, the engine’s acceleration will produce black smoke and the engine excessive exhaust emissions.
injection nozzle spring force gasket, armature stroke, lift gasket and solenoid valve spring force gasket determine whether exhaust restriction and injector fuel supply reach standard
LL: Test if the idle fuel supply reaches the standard
This test detects oil injection is too much will cause engine idle smoke, otherwise if the oil injection too little will cause engine idling easy to stall, or difficult to start.
The uneven of oil injection causes the unstable rotation speed of engine , making noise, and increase the engine swing in the acceleration process.
Each injector error should be controlled within 2mm3/HH when adjusting.
Idle speed fuel supply quantity mainly by adjusting the nozzle spring force gasket.
VE: Test whether the pre-injection meets the standard
This test detects when oil injection is too much will cause cylinder knocking while the engine is working and the exhaust emissions is not up to standard (smoke).
While when oil injection is too little will cause big noise while the engine is working, the engine is difficult to start, the engine weak acceleration, slow response of injector.
Each injector error should be controlled within 0.5mm3/HH when adjusting.
Recognition of G3S103 Diesel Injection Nozzle Code
G3S103 Diesel Injection Nozzle code is engraved on the outer edge of the nozzle body, see as below:
▲ Before replacing the Diesel Injection Nozzle, this code should be used to check on the special nozzle tester that all parameters meet the requirements before installation. After installation, the code should be checked and modified with a special diagnostic instrument.
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