English
A commercial vehicle maintenance company specializing in regional logistics fleets required a more standardized approach to common rail injector remanufacturing.
The customer primarily serviced high-mileage diesel engines operating under long-duration and high-load conditions.
During injector maintenance procedures, the customer identified several recurring issues:
- Aged sealing components resulting from long-term exposure to fuel and thermal cycles
- Deformation of copper sealing washers after extended service periods
- Injector calibration deviations associated with shim wear
- Inconsistent repair outcomes caused by multiple spare part sources
The customer required compatible repair components that could integrate with existing testing and calibration procedures.
OTTO Diesel supplied injector repair kits tailored to the customer's injector models and maintenance requirements.
The kits included:
- FKM sealing rings
- Precision-machined copper washers
- Injector adjusting shims
- Matched service components
Each repair process followed a standardized workflow:
- Injector disassembly and cleaning
- Component inspection
- Replacement of wear parts
- Reassembly according to service procedures
- Test bench verification and recalibration
To support the customer's maintenance process, OTTO Diesel focused on the following factors:
Repair kit configurations were matched to specific injector platforms and OEM requirements.
Sealing materials were selected for compatibility with diesel fuel exposure and operating temperature conditions.
Critical components were manufactured with controlled tolerances to support injector calibration procedures.
Batch identification supported maintenance records and quality verification.
By implementing standardized repair kits and maintenance procedures, the customer established a more consistent injector remanufacturing workflow.
The project demonstrated that successful injector repair depends on component compatibility, dimensional control, material selection, and validation through standardized testing procedures.
OTTO Diesel continues to support diesel aftermarket customers with common rail spare parts and technical solutions for injector maintenance and remanufacturing applications.