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Home » New items » Bosch injection pump check valve for KAMAZ
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Principle of operation
The KamAZ injection pump provides a standard operating scheme. It includes the following stages:
1. Mechanical transmission of energy from the crankshaft to the camshaft.
2. Rotation of the latter, which triggers the movement of the pushers, moving the plunger with the help of springs and its own movement from its original position in the lower part of the sleeve to its upper part.
3. The piston closes the intake valve and builds up pressure in the space above the plunger.
4. The injector valve operates and sprays fuel inside the combustion chamber under pressure sufficient for self-ignition.
5. Draining excess fuel and moving the plunger to its original position, resulting in the opening of the inlet valve and starting a new operating cycle.
As the above description shows, the operating principle of the KamAZ injection pump is standard for any high-pressure fuel pump of a diesel engine. This is quite logical, since the main requirements for such a mechanism are reliability and durability. It is to ensure these parameters that in the manufacture of individual parts of the injection pump and, above all, the plunger pair, high-strength alloy steels are used, and the parts themselves - the piston and bushing - are carefully processed and ground to each other, thereby achieving the required level of tightness of the entire assembly.
Fuel system check valve: how to check the valve
Fuel system safety valve
It goes without saying that vehicle fuel systems are quite complex devices, which it is better not to approach without specific knowledge. On the other hand, knowledge of hardware and some experience is already considered as an opportunity to independently repair this or that defect. For example, if a fuel system check valve requires attention.
Design
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Any check valve (OC) is nothing more than an element that ensures the movement of fuel in one direction. It can block the flow of unused fuel back into the fuel tank.
Its design, as a rule, implies the presence of a calibrated saddle made of soft metal. The valve allows gasoline or diesel fuel to pass in one direction, but when the engine stops, the valve automatically closes and the movement of liquid stops.
Fuel system valve and pipe
Despite the simplicity of the design of the bypass valve, its malfunction or its banal absence in the system can lead to great difficulties. For example, the normal functioning of the motor is impossible, and starting it becomes more difficult.
There is no need to confuse the OK with a pressure reducing valve. The latter is responsible for pressure stability, although it operates in conjunction with a check valve.
Read more about pressure reducing valve. It is responsible for equalizing the pressure in the section of the fuel rail where the fuel liquid enters the injectors. If it were not for this valve, the injectors would receive fuel under different pressures or without it, as a result of which they would not be able to transfer gasoline further into the chamber.
Pressure reducing valve or pressure regulator
The regulator stops supplying fuel to the injectors when the engine stops and the ignition is turned off. The shut-off mechanism simply operates, cutting off part of the fuel line. Gasoline remains only in the area between the fuel pump and the ramp, if OK. If not, there will be no fuel in the system; it will leak back into the tank.
Location
The OK can be installed in different places: in the fuel pump housing, on the ramp, or simply between the tank and the injectors. The exact location depends on the specific car model.
For example, on most diesel cars the OK is placed between the low-pressure pumping device and the injection pump. Here, in addition to its main functions, it is responsible for the stability of the pressure at the injection pump inlet. Examples: KAMAZ, Tatra, Man trucks, etc.
Where is the fuel system check valve located?
But in KamAZ vehicles intended for operation in arctic conditions, in Magirus truck systems, a check valve is installed in front of the heating system.
On VAZs with injectors equipped with 16-valve engines, the OK is installed either in the fuel pump or on the ramp. But in carburetor VAZs of the old type, on the “classics”, it is not there. But the function is provided. The role of OK is played by the fuel pump itself, installed on the BC.
Caring owners of old cars, including the Mazda 323 and Opel Cadet, modernize the fuel systems themselves by installing check valves closer to the carburetor or injector. This makes it easier to start the engine, because fuel is no longer drained back into the tank, even at the lowest temperatures or depressurization of any connections.
Problems
Why does OK fail? This happens quite often, since the market today has become more defective as a percentage. Chinese counterfeits at low and medium prices attract the attention of motorists who do not suspect a trick. It is worth installing such a part, and after a while problems arise.
How to check the fuel system check valve
If the part is of high quality, then the malfunction occurs for a natural reason - due to wear. As a rule, either the spring or the membrane deteriorates. It is extremely rare for the valve to fail completely, which is a credit to it.
Another common cause of failure that we have seen lately is low quality fuel. Gasoline or diesel fuel mixed with water is harmful to many parts of the fuel system.
Typical symptoms of an OK malfunction look like this:
- the speed changes unexpectedly in idle mode;
- the engine starts only after pressing the gas pedal, although previously it started only by twisting the starter;
- at low speeds the engine operates extremely unstable;
- Liquid leaks from the supply and return fuel pipes, although the sealing of the hoses is beyond doubt.
OK has a mechanical design. On the one hand, it seems to be good and can be easily fixed if you understand the mechanics. In fact, the element is non-separable, and it is impossible to diagnose its functionality using electronic devices, sensors, for example.
Ways to check functionality OK
Various methods are used to determine the serviceability of the valve. One of them is based on checking the pressure level. It is measured by a pressure gauge connected to that part of the system that supplies the engine with gasoline. The normal pressure level should be 3 kg/cm2 (passenger cars). Also, the level should not drop sharply when the engine is stopped. Otherwise, this also indicates a malfunction of the return valve.
Pressure gauge
Some experts advise checking OK by squeezing the return hose. In this case, if everything is in order with the valve, the pressure level should increase. The method is suitable for those machines in which the “return” is made of a rubber hose. However, many cars are equipped with metal pipes or the “return” is too short, it is impossible to compress it.
There is another diagnostic method, without a pressure gauge, suitable for engines that are unstable and have difficulty picking up speed. Again, the return line is pinched. At the same time, you need to monitor the operation of the internal combustion engine. If the engine speed increases and all cylinders are functioning normally, the OK is most likely faulty.
Obviously, nothing good can be expected from a damaged valve. A drop in engine speed, unstable cylinder operation, difficult starting, airing - all this will come sooner or later if the valve does not work.
Clamp the return line
It will be interesting to consider the reason for the airing of the system, which opens our eyes to the principle of operation of the OK. After stopping the engine, a certain amount of fuel liquid must remain in the chamber, awaiting the next start. If there is no valve or it is damaged, gasoline/diesel goes back into the tank, and air takes its place. Until the system is ventilated and the pressure is brought back to normal, the engine will not start.
Installing additional OK
It is recommended as an option for upgrading a system in which the original valve no longer holds (or does not exist at all). You just need to try to choose a high-quality valve, and the cross-sectional dimensions must be suitable. For example, some models of VAZ valves are not suitable for foreign cars. You can install them, but they don't last long. As soon as you accelerate sharply or climb a mountain, the valve slips and the car begins to choke.
It would be better to buy OK from parsing. Find the fuel pump of a specific car model, check the valve, if it works, take it. It does not matter whether the pump itself is running or not. The main thing is to hold the valve.
Fuel system check valve Nexia
All that remains is to embed the valve into the line, in any convenient place. For example, between the fuel pump and the filter. Then check on a hill or when accelerating to see if the car is choking.
Video: how to check the safety valve
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Purpose
The functional purpose of KamAZ fuel injection pumps does not differ from standard high-pressure fuel pumps used in diesel engines. It consists of solving several key problems:
· movement of fuel to nozzles connected to combustion chambers;
· pumping fuel pressure to the level necessary for its self-ignition;
· dosage of diesel fuel, ensuring engine efficiency and the most complete combustion of fuel;
· determination of the optimal time for fuel injection into the combustion chambers;
· cleaning of fuel during its transportation.
The fuel injection pump of any diesel engine plays an extremely important role for the operation of the entire power unit. It was the invention and gradual improvement of high-pressure fuel pumps that led to the fact that diesel units using diesel fuel first successfully competed, and then simply began to outperform engines designed to use gasoline.
It is important to note a feature that is typical specifically for trucks, the class of which includes all KamAZ models. We are talking about the need to develop serious power, combining it with efficiency and environmental friendliness in work. The use of fuel injection pump and a modern common rail fuel injection system allows us to successfully solve the problem, which, along with the affordable cost, is an important competitive advantage of the products of the Kama Automobile Plant.
Malfunctions and repairs
You can repair KamAZ fuel injection pump yourself if you have the necessary tools and equipment.
Main fuel injection pump malfunctions and reasons for their occurrence:
- Water in the fuel mechanism. This breakdown may indicate a malfunction of the fuel filter element, diluted fuel, or a leak in the fuel drives.
- Reduced and uneven supply of working fluid. In this case, it is recommended to check the plunger for damage, and also inspect the discharge valves and rack clamps. The capacity of the injectors should be checked.
- The diesel fuel is running out. The cause of this breakdown may be a leak in the fuel drive. The damaged element should be replaced.
- The drive is tearing. It is recommended to inspect the crankshaft, as well as the main components of the power unit for damage and foreign bodies.
- Delay of the working fluid injection system. Such a malfunction can be caused by damage to the plane of the adjusting bolt of the pusher element, the roller axis and failures in the rotation speed of the cam shaft.
Conclusion
The KamAZ injection pump is an important element of the diesel engine of trucks produced by the Kama Automobile Plant. The operational and technical characteristics of the high-pressure fuel pump largely determine the efficiency and operating efficiency of the entire diesel engine. Therefore, it is not surprising that the plant pays the closest attention to the development and improvement of fuel injection pumps.
A prerequisite for long-term and trouble-free operation of the fuel pump is regular maintenance of a unit that is so important for the operation of the engine and the entire truck. It is best to carry out diagnostics, maintenance and repair work in specialized service centers that have both the necessary equipment in the form of testing stands and a staff of professional and qualified specialists.
