1999 Jackaroo fuel system.

Submitted: Tuesday, Oct 25, 2005 at 19:40
ThreadID: 27559 Views:3167 Replies:3 FollowUps:3
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I'm hoping somebody may know more about this than the Holden agents. Referring to the common rail system of the turbo diesel Jack, we found that the modification to the injectors supplied by Holden consisting of a steel sleeve and O ring was faulty. The O ring was too "fat" and as soon as the injector was tightened down the O ring was ruptured leading to fuel leaks and difficult starting. This has now been rectified with "thinner" O rings which seems to have solved that problem. But what I would like to know is how this leaking O ring allows fuel into the cylinder? The copper seals were fine, and I would have thought that when the engine was switched off the injectors would be firmly closed either electrically or by a spring? Am I wrong? Peering down the injector hole I can't for the life of me work out which is the common rail port and I am reluctant to dismantle an injector just to have a look. If anyone can explain this to me or better still come up with a diagram of the injectors and ports in the cylinder head I would be eternally grateful. Previously after leaving it over night it would refuse to start until I gave the priming pump a few pumps, it was always slack. Now the priming pump stays firm and it starts with no problems. Sorry to be so long winded about this but it is something that has puzzled me for some years. cheers to all
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Reply By: Member - Darryl - Tuesday, Oct 25, 2005 at 19:56

Tuesday, Oct 25, 2005 at 19:56
Try here ,plenty of info and ex Gmh Tech's

http://forum.australia4wd.com/index
AnswerID: 136318

Follow Up By: The Don - Wednesday, Oct 26, 2005 at 11:34

Wednesday, Oct 26, 2005 at 11:34
Many thanks Darryl, that is a very useful site for Jack owners. I have experienced some of the weird problems that show up on that site and it would seem that I can expect a few more> Starting to feel exposed! Cheers, Don.
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FollowupID: 390205

Reply By: Rigor - Wednesday, Oct 26, 2005 at 09:04

Wednesday, Oct 26, 2005 at 09:04
Hi Don I have 3.0 L Jack and have removed the injectors for the upgrade. You are right about fuel leaking into the cylinder , just can't happen unless things are horribly wrong. The copper ring is a heat shield and compression seal between the combustion pressures and the fuel rail which is in the head, if that was leaking there would be massive pressures in the fuel rail as the bottom O ring would not keep it out. Maybe they were referring to the fuel getting into the oil which is what the upgrade was all about . You said that you couldn't see the common rail for the fuel , well you are right , it is down in the head and simply an orifice that lines up to the fuel inlet on the injector (between the two O rings) and the high pressure oil inlet ( to supply the injection pressure)is at the top where it bolts onto the high pressure oil rail . Hopes this helps , I may be able to supply a soft copy of the injector assembly if you wish .

Cheers Dave L.
AnswerID: 136419

Follow Up By: The Don - Wednesday, Oct 26, 2005 at 11:43

Wednesday, Oct 26, 2005 at 11:43
Thankyou Dave, I think you have hit the nail on the head with the common rail fuel getting into the high pressure lub. oil and ending up in the crankcase. Guess that's what the additional sleeve and O ring was all about. I thought the sump oil level was rising slightly, it certainly wasn't going down. Would cretainly appreciate a soft copy of the injector assembly if it is not too much trouble. Thanks again, Don, bellairs@wn.com.au
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FollowupID: 390207

Reply By: Rigor - Wednesday, Oct 26, 2005 at 12:09

Wednesday, Oct 26, 2005 at 12:09
Don I have sent an email with diagram.

Just one point when the fuel leaks past the O ring it simply flows to the sump with the oil from the cam lubrication .It Has nothing to do with the high pressure oil rail.

Dave L.
AnswerID: 136450

Follow Up By: The Don - Friday, Oct 28, 2005 at 18:54

Friday, Oct 28, 2005 at 18:54
Hi Dave, Many thanks for the injector diagram etc, I now have a reasonable idea of what this fuel injection system is all about, happy 4WDriving, Don.
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FollowupID: 390597

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