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Recently updated on September 20, 2023 at 09:32 am
The Injectors or the injection valves are there to supply the engine with the exact amount of fuel before combustion. In the case of injection nozzles, diesel engines are also referred to as injectors. Often it happens, however, that the injectors Coke or are generally contaminated, causing them to wear out or clog. This can happen with both gasoline and diesel engines. If you're lucky, the problems can get through additives be eliminated again.
Overview of the topics
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- Benefits of Fuel Injection?
- Manifold injection vs. Direct injection
- Why injectors can be defective
- How are defective injection nozzles noticeable?
- The cleaning of injection nozzles by an injection system cleaner
- The cleaning of injection nozzles in an ultrasonic bath
- Have the injection nozzles professionally cleaned
- What does it cost to clean injection nozzles?
- Inspection of the injection nozzles by a workshop
- What do new injection nozzles cost?
- Tutorials: cleaning the injectors
- summary information
Benefits of Fuel Injection?
Due to the many advantages, it came to the end of the 80s that they were used until then carburettor have been replaced by the new petrol injection. Modern injection nozzles are solenoid valves that are electronically controlled with extremely high precision. This process used to be done mechanically. The Engine control unit connects the injection nozzles with other components and sensors that are essential for combustion. The greatest advantage that gasoline injection brings with it is that fuel consumption is significantly reduced by such an injection due to the higher efficiency. Furthermore, regulated by the injection Catalysts be installed, which results in cleaned exhaust gases. (Back to overview)
Manifold injection vs. Direct injection
There is at least one injector for every cylinder in an engine. The injection nozzles are either located in the intake tract (in this case one speaks of an intake manifold injection) or in the combustion chamber of the cylinder (this is referred to as direct injection), where they are responsible for atomizing the fuel. Some modern models, for example the Audi R8 V10, also have a combination of manifold injection and direct injection. If both variants are installed, the two injections alternate in order to reduce nitrogen oxides, which is ultimately noticeable through improved power delivery. However, an overpressure must be provided so that a corresponding atomization can be carried out. For example, the pressure with manifold injection is between 3 and 6 bar, while with direct injection it can even be up to 350 bar. This is only surpassed by modern common rail diesel engines: With these engines with direct injection, the pressure can reach an incredible 2500 bar. (Back to overview)
Why injectors can be defective
The injection nozzles have extremely fine bores, which can clog relatively quickly and thus have defects in the long term. This can be the case, for example, if unfiltered fuel was used. Such problems should, however, be resolved quickly, as fuel consumption increases and optimal performance is no longer given. With direct injection it can even damage other components. For example, it can happen that holes burn in the pistons, as no mist is formed, but a real jet that burns on the bottom of the piston. In the case of direct injectors, the edges of the injection nozzles can fray over the long term, which also counteracts efficient injection. The most common reason for a defect, however, is coking of the nozzles, which in some cases can ultimately lead to a permanent failure. Other defects that can occur are deposits caused by additives, damaged cable connections to the control unit and short circuits in the solenoid coils located in the injection nozzles. In addition, the sealing rings can wear out, which can lead to fuel loss. (Back to overview)
How are defective injection nozzles noticeable?
How noticeable a defect is depends on how many injection nozzles are defective and also on how severe the damage is. Symptoms of a defect can be, for example, more or less pronounced drops in performance, poor exhaust gas behavior, difficulties starting, increased fuel consumption, restless idling, the temporary or permanent lighting of the Engine control lamp or even an engine knock and combustion misfires. As already mentioned, a defect in the injection nozzles should be rectified immediately, because the consequential damage can sometimes be enormous. For example, if unburned fuel gets into the catalytic converter or the Particle Filter these components can be severely damaged or even destroyed. If the fuel washes off the oil film on the cylinder wall, it can cause piston seizure. So, as you can see, broken injectors are not to be trifled with and as soon as you experience the above symptoms, you should go to the workshop as soon as possible. (Back to overview)
Cleaning injection nozzles with injection system cleaner
In older vehicles in particular, cleaning the injection nozzles can ensure improved injection behavior and often better exhaust gas behavior. If the injection nozzles are to be cleaned with an injection system cleaner, it is essential to note which cleaner has been approved by the vehicle manufacturer. After all, the additive then flows through the entire fuel system and must also withstand the high pressures. (Back to overview)
Cleaning of injection nozzles in an ultrasonic bath
If the injection nozzles are particularly dirty and can be easily removed for this purpose, as is the case with intake manifold injection, cleaning in an ultrasonic bath is recommended. Here it can also be an advantage to clean or even replace the microfilters, which are often located above the nozzles. New sealing rings should also be installed at the same time as new injection nozzles are installed. (Back to overview)
Have the injection nozzles professionally cleaned
If you do not want to clean the injection nozzles or injectors yourself, professional cleaning is also possible, which is offered by some companies. If you choose this type of cleaning, the valves are also activated - the nozzles open and close, which improves the efficiency of the cleaning. Companies that have specialized in this cleaning are also able to determine the jet pattern of the nozzles and can also check the flow rate and throughput. (Back to overview)
What does it cost to clean injection nozzles?
How much it costs to clean the injectors in the end depends on the type of injectors, engine and vehicle type. If intake manifold injectors are cleaned, this is the cheapest and costs around 20-30 euros for a nozzle. With direct injection, the costs are between 30 and 80 euros. So-called piezo injectors are often built into a diesel engine, and cleaning costs between 60 and 85 euros per injector. Note that additional costs for installing and removing the nozzles are added to these prices, which is more expensive with direct injectors, as the nozzles are usually more difficult to reach here. If it is a diesel engine, its stuck injectors can only be removed with a special tool. Depending on how many nozzles there are and how easily they can be reached, the working time can easily be over 6 hours. Sometimes the nozzles are also destroyed if they are unusually stuck. (Back to overview)
Inspection of the injection nozzles by a workshop
Workshops are able to check the injectors without removing them. This works, for example, by reading out the fault memory and by checking the cable connections with a multimeter. A fuel pressure test can also be used to check that other components are functioning properly - for example a defective high-pressure pump or a damaged fuel pressure regulator. (Back to overview)
What do new injection nozzles cost?
Again, the costs are different. Valves that work in the intake manifold cost around 40 euros, while injection nozzles for modern direct injectors or injectors for common rail diesels can cost more than 200 euros. This is of course particularly annoying when several or perhaps even all of the nozzles have to be replaced. (Back to overview)
Tutorials: cleaning the injectors
Injection nozzles / injectors defective? The symptoms, the replacement, the cleaning, the costs at a glance:
- The injection nozzles are also referred to as injection valves / injectors, depending on the engine design.
- They meter the amount of fuel to be injected and work extremely precisely. The fuel injection is either indirect (e.g. in the intake manifold) or directly into the respective cylinder (direct injection). They are activated by the engine control unit, which calculates the amount of fuel required in each case on the basis of various measured values such as engine temperature, intake air temperature, load, etc.
- Defects are caused by leaks or fuel deposits, among other things.
- You should go to a workshop at the first sign.
- Symptoms / signs of broken injection nozzles or injectors
- increased fuel consumption
- The engine cuts out while driving
- odor of fuel in the interior
- knocking fuel combustion
- increased exhaust gas values within the framework of the general inspection
- Engine does not start
- Loss of power / vehicle accelerates poorly
- black exhaust
- bluish fumes
- Rough engine run / misfire
- The engine control lamp (MKL) lights up
- Fault memory entries such as "Injection quantity out of tolerance", "Misfiring cylinder x" etc. are available
- The injection quantities of the individual nozzles can be checked using diagnostic software - Can you confuse defective injection nozzles with what?
- depending on the symptom with combustion misfires, a defective ignition coil, defective spark plugs, etc.
- First, troubleshooting should be carried out in a workshop - possible causes for defective injectors
- fuel deposits (Injectors are getting clogged due to poor fuel or contamination in the system)
- Leaks, for example due to age-related wear (Injection nozzle "drips in")
- defective high pressure fuel pump (for example, when it has "eaten", metal chips enter the system and clog the injection nozzles / injectors) - known series with frequent problems
- Audi A6 4F (3.0 TDI engine)
- Audi A4 B7 (3.0 TDI engine)
- Mercedes Vito (W639 CDI) - Continue driving with defective injection nozzles / injectors?
- Can damage the catalytic converter or damage the engine
- If an injector is leaking in the direction of the combustion chamber and "drips in", the piston is stressed at certain points and can break - Effects of defective injection nozzles on the HU?
- with defective injection nozzles, the mixture formation is faulty
- The exhaust gas limit values are usually no longer complied with
- The general inspection is not passed with defective injection nozzles - Injectors / injectors and their replacement / cleaning
- The cleaning or repair of defective injection nozzles is not recommended, but it is much cheaper
- a defective injection nozzle should always be replaced with a new part
- Just replacing the defective nozzle (s) is usually sufficient
- If possible, however, all nozzles should be exchanged
- The exact procedure for removing the defective injector varies depending on the engine design
- Special tools are usually required
- Depending on the vehicle, first dismantle the engine cover and surrounding components such as the intake manifold, intake manifold, rail line
- If the nozzle or the injector cannot be removed, it must be drilled out
- After the removal, the new nozzle (s) can be reassembled
- The fuel filter should be changed at the same time
- New injection nozzles should be taught in using a diagnostic tester - Injectors / injectors swap, the cost
- Material costs vary
- the injectors from Otto engines (Petrol) cost between 30 and 400 euros per injection nozzle
- the injectors from diesel engines cost between 250 and up to 1.400 euros per injector
- Labor costs of around 80 to 500 euros per nozzle
- Manufacturers of spare parts are Pierburg or Bosch - Repairing the injection nozzles / injectors usually only costs around half the material costs compared to new parts
- Removal and installation of an injection nozzle or injector between one and four hours
- this depends on whether the injection nozzle / injector can be removed without any problems (Back to overview)
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