Injector Calibration / Hot Swap

Price: $176.00

This item is in stock

Detailed Description

Specifications

Injector Nozzle replacement and/or Pressure Calibration

We perform Injector nozzle replacements and/or set the injector break pressures back to new specifications and tolerances. Unlike other shops that claim to be able to set "Break Pressure" we have the equipment to precisely set both Pilot and Primary break pressures in two stage injectors using a state of the art digital pressure test bench. This insures perfect and precise balance in respect to fuel pressure and the resultant quantity delivered to all cylinders. We start by completely disassembling and ultrasonic cleaning all internal components including the nozzles and needles. Ultrasonic cleaning insures all parts are completely stripped of varnish and gums which normally occur in all fuel systems and lead to degraded injector performance and flow imbalance. Injectors are then reassembled and the pressures are reset to new tolerances. After all pressures and spray patterns are set and evaluated the injectors are coated with a high temperature coating that protects the injectors from corrosion and improves the aesthetic value of your newly conditioned injectors.

This service cleans, tests, and calibrates your injectors. (set of 4) This is a great way to ensure that your injectors are performing to factory specifications. Both pilot and main injection break points are set to our exact pressure setting based on your engine configuration and tuning.

Exclusive Pressure Setting Options :

Stage 1- Low Smoke for cleanest operation [ ideal for stock or lightly modified vehicles ]

Stage 2 - Low Smoke for Tuned Vehicles
Please note: Stage 2 and 3 are the most popular settings and we can always recalibrate

Stage 3- Low Smoke for vehicles with Turbo, Tune, Clutch and also exhaust, camshaft, and intercooler upgrades
Please note: Stage 2 and 3 are the most popular settings and we can always recalibrate

Stage 4 - Low Smoke for vehicles with all of the above and full upgrades including Camshaft, Exhaust, Intakes and cylinder head work

Stage 5 - Custom Settings for very highly modified vehicles

This is the only way to properly set up your new Genuine Bosio nozzles for ideal performance! This extra attention to correct nozzle / injector technical specifications will optimize performance, smooth engine operation, correct fuel delivery, and provide the best fuel efficiency.

If you'd like upgrade nozzles installed, please select from any of the Genuine Fratelli Bosio nozzles, and add to your order.

Digital Injector Calibration and Balancing

Digitial Calibration and Balancing

Digital pressure sensing is used to read and and record injector data. The Pressure sensor is certified under ASME B40.7-2005 standards which permits accuracy to +/- 0.5% and a pressure range expanded to over 600 bar! Also due to the high speed cycling of the nozzles the new digital calibration equipment was selected due to its ability to read ALL pressure cycles that occur within a 10 millisecond window! To insure the highest level of accuracy the pressure resolution will be reduced to .068bar meaning extremely accurate pressure readings during all injector opening phases that no analog pressure gauge can display.

In House Digitial Flow Validation (NEW for 2011)

Digital flow validation is used to read and and set every new nozzle that we sell. This is performed on the nozzles prior to installation allowing us to insure that every nozzle perform exactly to specification.

We can generate a complete report for every nozzle and compare every critical aspect of that nozzle performance. This is the equivalent of a "Dyno" for nozzles. We can evaluate delivery rate, peak delivery volume as well as response to flow at all ends of the flow range.

This new system uses state of the art Flow sensing technology which evaluates all flow characteristics by replicating the flow of the fuel passing thru the nozzle. Long gone are the fill tubes you may have seen, this new generation test bench samples flow rates as often as 400 times per second allowing a complete evaluation of a nozzles performance not previously possible.

This is especially helpful for companies developing a nozzle design or for the performance oriented driver/tuner looking to get the maximum performance from a nozzle combination.

Direct Injection (DI)

Two Stage injector Calibration

Unlike older "IDI" or "Pintle" style injectors, two-stage injectors precisely meter and inject fuel at different intervals of every combustion stroke in order to control the pressure rise in the cylinder. The resulting softer rise in pressure greatly reduces the "Diesel Knock" formerly associated with diesel engines. This however results in an injector that cannot be set thru conventional methodology. Two stage injectors require multiple steps to insure both injection events occur within a very narrow window of pressure to insure that the fuel metering is not effected to maximize the ECU's control of the engines combustion and power output. Each injection event in normal operation can be as rapid as 1.5 milliseconds in duration while tightly controlling the amount of fuel injected to minimize engine emissions output.

Set Pressure Ranges

Each pressure is set at a predetermined value based on the ECU fuel mapping's expectation of injector performance. The pressures of each stage although independent have a reliance on each other to achieve the specified pressure that respective stage should begin to open at. Manipulation of one pressure without adjustment to the other will cause an erroneous pressure change on the other. Anytime one stage is changed the other too must be adjusted and set accordingly.

Spray Quality

Injectors have a certain expectation of durability in a specific application. The primary factor that determines the life of an injector nozzle is the quality of the fuel filtration. peak pressures at the nozzle holes can exceed 2000 bar, any amount of suspended matter can cause the fuel to act like a cutting jet rapidly eroding the nozzles precision machined hole geometry. It is accepted that no matter how good the filtration is, it is impossible to completely eliminate all particles from the fuel. So, even with ideal conditions some erosion of the nozzle is expected and will occur thus the reason nozzle fuel spray should be evaluated at regular intervals to reduce the likelihood of damage to the pistons combustion bowl and cylinders.

High Pressures Require High Precision Hardened Steel Shims

We only use the highest quality precision lapped hardened steel shims from Germany. These are the same shims used to set the pressures when your injectors were first produced at the factory. We stock the complete range of shim thicknesses which permits us to accurately set any pressure desired without compromise. Unfortunately we have found failed shims made from much softer stainless steel used by other shops when they have attempted to set the break pressures. Often the well intentioned shops revert to "stacking" of multiple thinner shims on top of the original shim to achieve the desired thickness. Use of stainless steel shims results in flattening and eventual disintegration of the shim within the injector. The failure of the shim is due to the extreme pressures generated by the rapid cycling of the nozzles and their internal mechanisms. The resulting loss of shim thickness and failure of the stainless shims leads to the injector falling from the set opening break pressures resulting in poor fuel quantity control and increased smoke output. Aside from pressures, the failing shims generate metal fragments that are free to circulate within the precision workings of your injectors and expensive high pressure fuel system.

Uncompromising quality and precision, Our promise to you

We treat every component as if it is going in our own personnel vehicle. We take ownership of your components and insure the absolute highest level of precision and workmanship that goes into them. If we can't promise to do it right, we won't do it at all.

Hot Swap $600 security deposit on Injector cores and loaner tools

Must be returned within 30 days to receive a refund of the security deposit.

Injector cores and loaner tools must be returned within 30 days to receive a refund of the security deposit. If good injector cores are not returned in a reasonable time frame; After 30 days 50% of the deposit is lost, and after 45 days 100% of the deposit is lost. We really wish this was not required, but we have received cores 8 months late. And , yes, if there are special circumstance we will make an exception

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