Injector Calibration / Hot Swap
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Injector Calibration / Hot Swap

Injector Calibration / Hot Swap
SKU: injcalib

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 factory specs. Or, you can select the calibration you prefer

Exclusive Pressure Setting Options :

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

-Factory Specifications

-Performance for increased fueling [ ideal for upgraded vehicles with larger turbos ]


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.

Ship injectors to:

Pete Baranko

Kerma Calibration

7544 W Middle Fork St

Boise ID

83709-6090

Please include with your injectors: your name, contact information, (phone, email, and return address) the nozzles you'd like installed, and your order number. (generated at checkout)

Return shipping will be included at checkout. Typical turn around time is 1 business day once we receive your injectors.

If you are using our Injector Hot Swap Program we will ship the new Genuine Bosio nozzle mounted and calibrated to you first and then you can return your injector cores to:

Pete Baranko

Kerma Hot Swap

7544 W Middle Fork St

Boise ID

83709-6090

 

===============

“Hot Swap” injector program. 

=== Purchase any set of Genuine Bosio ALH nozzles from kermaTDi and pay for Mounting, calibration and flow balancing and we will ship a set of ALH injectors mounted with your nozzles and eliminate downtime of your vehicle.

=== A $500.00 core deposit will be charged at the time of purchase (by typing "1" in the "HOT SWAP DEPOSIT" option below). Once we receive your used set of ALH injectors complete* and in serviceable condition** to us.... WITHIN 14 Days of delivery of your exchange injectors *** .... you will receive your full core charge back without any hidden fees or charges!  The core deposit is to ensure that we have good cores for the next customer and can keep these cars running well. This is a group effort to support better running TDI's.


=== *Complete injectors mean (3) injectors from cylinders 1, 2 and 4 as well as the #3 injector. The #3 injector is expected to arrive without the “T” return nipple and banjo bolt. Injectors must be returned un-opened and with the nozzles installed to prevent loss of internal components. Note: If you require the nozzles mounted in your core injectors be returned to you, a modest fee of $10.00 will be charged and the nozzles upon receipt by us will be removed, bagged and shipped back to you via USPS.

=== **Serviceable condition means no marring of the injector bodies such as vice grip marks or other surface damage to the return nipples and threads. The #3 injector must be in good condition without ANY damage, fraying or tearing of the sensor wire. If there is any damage to the injectors that renders them damaged or unserviceable we reserve the right to retain your full core deposit.

[High deposit level injectors require extra cleaning labor and fluids and may incur a $50 surcharge or cleaning to the required levels may not be feasible. This is most likely to occur with Waste Vegetable Oil or High Concentration Biodiesel... these nozzles and sometimes these injector bodies may not be usable. Please specify if you want these returned to you in the documents when you ship to us ] 

=== Note: To prevent damage to the injectors you must remove the injectors using a slide hammer thus extracting them upward and out of the head. This will prevent damage to the injectors and allows easy and quick extraction with minimal effort. This extractor is available for purchase at low cost through kermatdi and there are plans to make your own on the net. In either case using this extraction method is the surest way to remove the injectors without damage.

===***  14 Days from the day of delivery based on tracking information. The sooner we get cores back, the less time your fellow TDI owner has to wait for his set.

=== We realize that at times injectors may be damaged we would like to remind you that we offer a complete set of NEW injectors at very competitive prices shipped to you ready for install.


Please indicate the year of your vehicle below, as there is an adapter necessary for 2003 vehicles.

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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.

 

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 increasd 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 personal 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.

 

 

 

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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 milisecond 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.
 
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 independant 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 erronious 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 likleyhood of damage to the pistons combustion bowl and cylinders.

 


Drivebiwire

PRICE:  $135.00
 

Quantity 

Vehicle Year 

Pressure Settings 

"Hot Swap" Deposit $500.00 

Try these related products:
- SPRINT 520 -
- POWERPLUS 520 -
-POWERPLUS 764-
-POWERPLUS 357-
-POWERPLUS 502-

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