- Electronically tested
The first step is to ensure the injector is electrically sound by testing coil that it has a correct electrical resistance (ohms) and to test for any coil weakness.
- External Cleaning
Good injectors are then disassembled (Micro filter, seals, pintle caps and plastic spacer are removed) to begin our cleaning and restoration process. All external contaminants are removed in our parts and injector cleaning bath.
- Internal Ultrasonic Cleaning
Injectors are then placed in our ultrasonic tanks specifically designed to clean fuel injectors. The injectors are placed in the ultrasonic tank with a cleaning solvent while they are electronically activated. The ultrasonic waves are allowed into the fuel injectors to be cleaned and remove all internal contaminants.
- Back Flushing and Reverse Flow Pressure Cleaning
Once the injector has been cleaned ultrasonically, all units are individually back flushed to remove the broken dirt particles. These particles can not be removed thru the injection orifices so they are driven out thru the inlet of the injector. All injectors are then mounted on the injector flow bench in an inverted position allowing them to reverse flow at a considerable pressure. We run a high performance injector cleaning solvent through the injectors for 30 minutes, completing the cleaning process. This process assures us that all dirt particles from the injector are removed.
- Leak Test
Injectors are mounted on the injector flow bench in the correct position to begin the testing procedures. We apply 60 PSI of pressure (more than a regular multi-port fuel injection system) and maintain this pressure with no signal to the injectors for 60 seconds. This test is to ensure that there are no fuel leaks.
- Spray Pattern Test
The spray patter is then visually inspected applying pressure and holding the injectors statically open for correct spray form (Spray pattern may be different in some injectors).
- Static Flow Test
The amount of fuel delivered by each injector is measured by holding the injector continuously open at a constant pressured (normally 43.3 PSI / 3 BAR) for a predetermined period of time). During this test if there is a flow difference of more than 4% it is likely caused by dirt blockage since the injector components (spring & coil) are not being utilized at this time.
**If the static flow test fails, we will repeat the ultrasonic cleaning process and back flushing of the injectors as necessary to thoroughly clean the injectors.
- Dynamic Flow Test
The amount of fuel delivered by each injector is measured by activating the injector at different pulse cycles and RPMs at a constant pressure (normally 43.3 PSI / 3 BAR) for a predetermined period of time. (This test better simulates actual daily driving conditions). If the flow difference in this test is greater than the difference of the static test this would indicate faulty injector components (spring or coil).
- Final Cleaning and Polishing
All injectors are cleaned and polished to give the best cosmetic appearance and like new condition, internally and externally.
- New Components & Final Tests
When the injectors pass our final inspections, the injectors are then re-assembled with new replaceable components (Filter baskets, pintle caps, O-rings and seals).
A final test is performed with all new components installed. The purpose of this test is to make sure the filter basket; o-rings, seals and pintle caps are positioned correctly and are not disturbing the flow or the spray pattern of the injector.
- Lubrication & Packaging
For every set of injectors that we clean, a small bag of special lubrication (grease) is supplied for the client. This allows the individual to grease the seals (o-rings) just prior to installation. Each injector is individually bagged. A data sheet of all the injectors is included, as well as all old parts removed.