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| (Special note - this article will actually be referring to nozzle holder assemblies used in most direct and indirect engines other than the Cummins PT system and Detroit diesel) Several symptoms relate to possible injector problems. These symptoms include but are not limited to: oil dilution, engine running rough, a dead miss, smoke (white or black), a drop in fuel economy and starting problems. Injectors can suffer from a drop in opening pressure. This usually occurs after several thousand miles or hours in use. A drop of 200- 300 psi is normal and usually does not have a noticeable affect on the performance of the engine. If a pressure drop is more than 300 psi the injector should be reset to manufacturers spec. in order to assure peak engine performance. A second problem injectors develop is poor fuel atomization. The main purpose of a nozzle holder assembly is to break the diesel fuel into small enough particles that it will burn properly. An injection nozzle is lubricated by the diesel fuel and any lubrication problems such as water or poor lubricating fuel quality can cause the nozzle to stick. This will hamper it's ability to atomize the fuel properly. Another problem causing poor atomization is an improper valve seat. Sometimes due to contamination or wear the valve seat will become damaged. This also stops the injector from atomizing properly. In some cases a diesel injector cleaner in the fuel like Stanadyne's fuel conditioners will help in these situations. In more severe cases the nozzle will need to be removed from the assembly, cleaned and reset to the manufacturers spec. In most cases the nozzle tolerances are so close that once the nozzle is damaged it is not repairable and the nozzle must be replaced in the nozzle holder assembly. New nozzles must then be checked and set to manufacturers specs on a pop tester. All injectors rebuilt by DIS come with new nozzles for premium performance along with a one year unlimited miles/hours warranty.
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