Common Rail Systems are the future of diesel fuel injection technology in both commercial and passenger vehicles. While this technology first appeared in buses and trucks, it has been quickly adapted for passenger vehicles to share the benefits across as many applications as possible. These benefits include significant increases in power and improved performance whilst drastically reducing exhaust emissions, engine operating noise levels and fuel consumption.

Since the introduction of high pressure Common Rail Systems, Cornell Diesel Systems have continued to invest in diagnosis and repair processes to service these systems. All the major manufacturers including BOSCH, DELPHI, DENSO and VDO (CONTINENTAL) produce high pressure common rail systems. We are proud to have these leading manufacturers as our suppliers in an era of rapidly changing technological innovations in the diesel fuel injection industry.

At Cornell’s we ensure that our highly experienced and factory trained technicians are experts when it comes to the diagnosis, repair and testing of this evolving technology. Due to the extremely high pressures modern common rail systems are designed to operate at, the level of manufacturing tolerances is extremely small. Our technicians all understand the high level of cleanliness and finesse required when working with this technology. As a result, these components are carefully handled within a pressurised “clean room” which has a highly effective filtering system to maintain the air cleanliness within strict ISO guidelines.

About Common Rail Technology

Common rail technology was developed for Diesel engines to improve performance and reduce toxic emissions and is now utilised in passenger cars, trucks, buses and many other diesel powered applications..

Common rail technology is responsible for the massive growth in diesel powered passenger car applications over the past few decades due to massive reductions in exhaust emission levels, vastly improved power and performance, reduced engine operating noise and lower fuel consumption.

How does Common Rail Fuel Injection work?

Modern day Diesel Common Rail Systems typically reach extremely high pressures, approximately around 2,800 BAR or 40,000psi. Whereas traditional diesel injection systems relied on mechanical governors and hydraulic pressures to control injection quantities and timing, common rail systems are precisely controlled electronically from an Electronic Control Module (ECM). The ECM receives inputs from a range of sensors on the engine and engine subsystems. Upon receipt of these inputs the ECM calculates optimum fuel injection quantity and timing to ensure performance, fuel economy, emission and noise levels are optimised.

Servicing Common Rail

Specialist knowledge is required for the diagnosis and repair of this technologically advanced fuel system. To produce such high injector pressures, the system components are manufactured to very tight tolerances, demanding the use of a pressurised “clean room” with highly effective filtering systems for all assembly work. Equipment that is serviced in an uncontrolled environment is prone to premature failure. Cornells made a substantial financial commitment in 2009 to invest in the facilities, equipment and training to meet the stringent compliance levels required to service and repair common rail systems and as such were appointed exclusively by DENSO in Australia to remanufacture Common Rail Injectors. In 2016 Cornell’s raised the bar, building a state-of-the-art service centre, fully incorporating clean room conditions and strict temperature  control throughout the build and test rooms, thereby committing to a level way beyond manufacturer’s requirements.