Umair Gaines
Common rail Cummins injectors are a type of diesel injector that debuted in 2003. They are known for their quiet, clean-burning, and powerful performance. The injectors are electronically controlled and can provide a significant increase in horsepower. There are two types of common rail diesel injectors: solenoid and piezo. Solenoid injectors are energised via a solenoid that takes orders from the ECM, while piezo injectors use piezo crystals energised by an electric pulse to open. Common rail Cummins injectors have a lifespan of around 100,000 miles, but there is variation in failure rates, and they can be rebuilt or replaced.
| Characteristics | Values |
|---|---|
| Injector type | Solenoid and piezo |
| Injector life | Generally, 100k miles is the minimum, 200k miles is prime replacement territory |
| Injector damage | Minimal leakage, no oil-to-fuel transfer pressure, pressurized spring cavities |
| Injector nozzle size | Depends on horsepower goal |
| Injector maintenance | Can be rebuilt |
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What You'll Learn
Common rail injectors are electronically-controlled
The common-rail injector is a solenoid-style injector that features two pressure chambers. It is energised via a solenoid, which takes its orders from the ECM (Electronic Control Module). This type of injector is found in ’01-’10 Duramax engines, ’17-present Duramax’s, and ’03-current Cummins power plants. The solenoid injector is the most commonly used (and modified) in the industry.
The other type of common-rail injector is the piezo injector, found in the LML Duramax and 6.7L Power Stroke. Piezo injectors are energised by a quick electric pulse, and the injector opens faster than its solenoid-type rival. However, while piezo injectors are quicker to open, they are slower to close.
The common-rail injector has brought about a new era of diesel engine performance, with quieter, cleaner, and more powerful engines. The true potential of the electronically-controlled high-pressure common-rail was realised when the aftermarket got a hold of it. Through ECM tuning alone, another 200-250 hp could be added to a truck’s performance, thanks to the factory injectors and high-pressure fuel pump.
The common-rail injector has also opened up new possibilities for modifications and upgrades, with the most common upgrade being the instalment of a larger, higher-flowing nozzle. This has led to a whole new world of possibilities for diesel engine performance and has pushed the boundaries of what is possible with diesel technology.
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Injector types: solenoid and piezo
In the world of common-rail diesel injectors, there are two types: solenoid and piezo. Solenoid injectors are the most common type, featuring two pressure chambers and are energised via a solenoid, which takes its orders from the ECM. They are highly successful in the market and are used for all on- and off-highway applications in cars up to light-duty vehicles. The injectors have a modular construction and can be adapted to the customer's needs.
The CRI2 solenoid valve injector, for example, injects fuel into the cylinder in the amount required for economical combustion, independent of the driving situation. It allows for up to ten individual injections per injection cycle. The injection process is initiated by the control unit via an electrical connection.
Piezo injectors, on the other hand, are made of piezoelectric crystals that produce a minuscule amount of electricity when pressure is applied. This process is reversible, as these materials also expand slightly when electricity is applied to them. This expansion is very small, with a 0.02-inch thick crystal expanding by only 0.00002 inches when hit with 140 volts of electricity. Hundreds of these crystals are stacked together to achieve the desired amount of movement. Piezo injectors open and close faster than conventional injectors, allowing for more precise control of the injection interval and improved combustion. They can also inject several times during a single combustion cycle, reducing emissions and limiting soot in diesel engines.
Bosch's piezo injectors are available for pressure levels between 2,000 and 2,700 bar and are used in the premium car segment and light-duty vehicles. They are slimmer than solenoid valve injectors and can be adapted to different customer needs, such as lifetime, nozzle design, and injector length. The CRI3 piezo injector, for instance, allows for short injection intervals and up to ten individual injections per injection cycle.
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$48
Injector maintenance and replacement
The 6.7L Cummins diesel engine is known for its power and efficiency, and its injectors are crucial for performance and emission control. The engine is commonly used in heavy-duty trucks, commercial vehicles, and RVs, and has six injectors, one per cylinder, to ensure each cylinder receives adequate fuel.
Maintenance
To ensure longevity, regular oil changes and fuel filter replacements are required. Driving conditions such as frequent towing, heavy loads, or stop-and-go traffic can accelerate wear, so it's important to monitor for signs of injector wear or failure. These include rough idling, misfires, reduced fuel efficiency, or black smoke from the exhaust.
Fuel and air filter blockages can impact performance, so regular replacement is crucial. Quality diesel helps reduce injector wear and carbon buildup, extending lifespan. It is also recommended to use specialised fuel system cleaners to remove carbon buildup and impurities from injectors and fuel nozzles. If engine performance declines or fuel economy decreases, injector cleaning and calibration may be needed.
Replacement
Aftermarket and remanufactured injectors for the 6.7L Cummins diesel engine do not typically require programming due to meticulous adjustments and testing during production. However, proper installation is crucial for optimal performance. Changing injectors on this engine requires precision and attention to detail. It is recommended to park the vehicle on a flat, level surface and engage the parking brake.
Common Rail Injectors
In the world of common-rail diesel injectors, there are two types: solenoid and piezo. The former is the most commonly used and modified in the industry, found in ’03-current Cummins power plants. The latter, found in the LML Duramax and 6.7L Power Stroke, is faster to open but slower to close than the solenoid type.
The most common upgrade for a common-rail injector is the installation of a larger, higher-flowing nozzle. When Cummins adopted the high-pressure common-rail system in 2003, it resulted in the quietest, cleanest-burning, and most powerful 5.9L engine it had ever produced. The factory injectors and high-pressure fuel pump were capable of supporting an additional 200-250 hp through ECM tuning alone.
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Injector damage and failure
In the early days of common-rail injectors, a second high-pressure fuel pump was often added to the Cummins engine to manage the pressure. Over time, advancements in stroker pump technology have made it possible to rely on a single, larger displacement pump to meet the required pressure needs. Nevertheless, the high pressure can still lead to injector damage if not properly managed.
One specific issue with injector failure is related to the spray pattern. For example, using the wrong injectors can result in a meltdown, as they may spray fuel outside the bowl. This is a known issue with certain injector models, such as the 4.5+ injectors mentioned in one source. Therefore, it is crucial to select the appropriate injector for the specific engine and application to avoid such problems.
Additionally, injector damage can occur due to modifications or upgrades made to the common-rail system. While the factory injectors are designed to handle a certain level of pressure and performance, modifications can push them beyond their limits. Upgrades such as larger, higher-flowing nozzles or higher-horsepower configurations may require corresponding upgrades to the injectors to handle the increased demands.
To prevent injector damage and failure, it is important to carefully consider any modifications and ensure that the injectors are compatible with the specific engine and application. Regular maintenance and monitoring of the injectors and the fuel system as a whole can also help identify potential issues before they lead to failure.
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Injector performance and fuel economy
There are several ways to improve injector performance, including:
- Upgrading to higher-flowing injectors: Higher-flowing injectors can deliver more fuel to the engine, increasing power and performance. However, this modification also requires upgrading the fuel pump and increasing the size of the fuel lines to accommodate the increased fuel volume.
- Maintaining rail pressure: With the use of higher-flowing injectors, maintaining rail pressure becomes crucial. In the past, this often meant adding a second high-pressure fuel pump, but recent advancements in stroker pump technology have made this less necessary.
- Adjusting the fuel pressure regulator: An adjustable fuel pressure regulator can help ensure that the injectors are running at the optimal fuel pressure, which can improve fuel efficiency.
- Cleaning the fuel injection system: Dirty fuel injection systems can hinder performance, so regular cleaning is important. Electronic fuel injection systems typically require cleaning every 20,000 miles.
- Using a fuel treatment or catalyst: Adding a fuel treatment or catalyst to the tank can help improve fuel economy and get the most out of each fill-up.
It is important to note that when making modifications to the fuel system, such as installing larger injectors, other components of the system may also need to be upgraded to accommodate the changes and prevent engine problems. Additionally, the ECU (engine control unit) may need to be reprogrammed to ensure optimal performance.
In terms of fuel injector types, common rail Cummins injectors are typically solenoid-style or piezo. Solenoid injectors are energised by a solenoid that takes orders from the ECM (engine control module), while piezo injectors use piezo crystals energised by a quick electric pulse, allowing for faster opening but slower closing than solenoid injectors.
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Frequently asked questions
Yes, common rail Cummins have electric injectors.
Generally, 100,000 miles is the minimum injector life, and 200,000 miles is prime replacement territory.
You can pull the injectors and send them to a shop to get flow-tested and checked out.
There are a few options for getting common rail Cummins injectors rebuilt, including Industrial Injection, Source Automotive, and SmartyPower.com.
