IC Engine Injector Sleeve O-Ring-Field Failure Resolution

Failure of Injector Sleeve O-ring was observed at Diesel engine particular in specific vehicle application. And the failure is on coolant leakage from cylinder head assembly. In general, failure causes may be due to assembly, rocker cover gasket issue, water pump failure, improper gland fill ratio in injector sleeve, improper material selection etc., In this study Injector assembly including, sleeve, O ring seal were dismantled and put up on the detailed investigation. Based on analysis, Injector sleeve O ring crack with black burn marks observed in all the failed assembly. O-Ring material is silicone rubber and after thorough study on the failed O ring its revealed that failure is due to high temperature spike in the system and material used is not suitable for the temperature and higher thermally stable material selected for the O ring to prevent and avoid the failure in particular vehicle application Keywords: IC Engine, Injector, Failure, Sleeve O-Ring, Injector sleeve, TGA analysis, Rubber Oil resistance, Engine oil immersion