FUEL INJECTOR TESTING
FUEL INJECTOR CLEANING
FUEL INJECTOR SERVICE
OUR PROCESS...STEP BY STEP
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Fuel injectors are highly susceptible to fouling from foreign particles. Foreign particles may be introduced from several sources as itemized below and elsewhere on this site...
1) The injector pintle and/or pintle seat are fouled from "baked on" or "burned on" fuel additives...(olafins), which impair the injector from providing a properly atomized spray pattern, and/or cause the fuel spray pattern to be discharged off angled, and/or cause the injector seat to "leak", and/or cause the fuel flow rate to be altered, or any combination of these.
2) The injector filters may be clogged from foreign particles introduced from an improperly maintained fuel supply system. (ie. rust in the supply lines, rust in the fuel rail, rust in the tank(s) , degraded rubber fuel hose, and/or water in the fuel or the fuel tank, causing a reduction of fuel supply to that specific cylinder.
3) The injectors may be damaged , as a result of improper handling during customer handling, or removal from the engine.
My shop area is carefully cleaned and maintained to avoid injector contamination, and the equipment is likewise carefully maintained, to provide professional results with every injector serviced.
With the above said...following is a detailed explanation of how your injectors are cleaned and tested.
A) Injectors are received and customer information and injector information is logged. Customer receives an e-mail notification of receipt of injectors.
B) Injectors are externally cleaned of dirt, oil, etc., via a combination of petrol flushing, clean pressurized filtered air, and wiping and brushing. If required, they are ultrasonically cleaned in a separate ultrasonic cleaner. Injectors with external light rust, are wire brushed to remove surface rust and loose paint particles. Rusting that pits the external surface requires additional cleaning steps, and possible added labor cost.
C) Injectors are then scribed with an identification number. This insures that proper recording and charting of each injectors' performance is maintained throughout the servicing and cleaning. If customer had provided numbers on the injectors that correspond to engine cylinder numbering, we will maintain cross references, to faciitate customers' engine fault diagnostics.
D) Injectors can now be visually inspected for any obvious signs of external damage. Cracked or missing pintle caps, corroded electrical pins, external rust, etc.
E) Each injector is now tested for ohm resistance and shorted/grounded coil windings for conformance to mfg. specifications. Any injector failing this test is excluded from further servicing. We also check the condition of the electrical connections for rust/corrosion which may affect proper electrical contact, and current flow. If necessary, the connectors are sanded clean. It should be noted here that injectors RARELY fail due to faulty injector coils, and this test may not be carried out, unless or until all other testing and cleaning warrants such testing.
F) Pintle caps, filters, o-rings, spacers, hoses, bushings, (as applicable) are removed and discarded as injectors are readied for bench testing and cleaning. With filter removed, each injectors' internal condition (as well as the filter) can be inspected for rust or corrosion. Internal rusting of the injector is usually non cleanable, although they may be cleaned to determine if the cleaning process will remove slight rusting.
G) Injectors are now mounted on the ASNU flow bench for a precleaning leak down test of the pintle/pintle seat, and injector body joint/seal integrity. The leak down test will reveal any mechanical defects in injector body joints. It will also reveal any leaks between the injector pintle and the pintle seat, whick may be due to those foreign particles, or rust. Injectors are tested at 1, 2 and 3 bar during this test . Results are noted.
H) Next step is the injectors are tested for pre-cleaning spray pattern shape. The injectors are tested at 3 bar pressure. This test will reveal any distortion of spray atomization pattern, or a pattern which is off-angled.
I) The next test process involves cc flow volume testing of each injector. Injectors are dynamicaly pulsed at 50% duty cycle (half time on - half time off), normally at 3 bar, for a period of 30 or 60 seconds, and results are logged. Flow results will be usually be reported to the customer at 60 second flow rate...the industry standard.
J) Injectors are now removed from the test bench, air and cloth dried, internally and externally cleaned of flow solution, and readied for ultrasonic cleaning.
K) Injector pintles are now submerged in a specially formulated cleaning chemical, while at the same time, pulsed, and subjected to ultrasonic waves. The cleaning process runs in 10 minute cycles, and cleaning may continue longer subject to results of the pretesting.
L) After ultrasonic cleaning, the injectors are retested for leak test, spray pattern shape, off-angled spray direction, and flow volume. No pintle leakage, matching spray pattern shapes and spray angle, and no more than 3% flow volume variation is considered acceptable for daily driving conditions. Post cleaning results are noted.
M) Pre-cleaning and post-cleaning test info is compared for each injector and cc flow rate % differences are noted for each injector.
N) Dynamic flow volume is averaged for the full set, both pre cleaning and post cleaning average flow for the set, and % average difference for the full set is noted.
O) Standard deviation for the full set is calculated, both pre cleaning and post cleaning, and the % difference is noted.
P) A post cleaning static (wide open) cc flow rate (for the set) at 60 seconds, at 3 bar, is calculated from the applicable above cc volume flows. 3 bar testing, at 60 seconds, at static (wide open) is the industy standard for measurement of injector flow rates.
Q) Each injector is now internally lubed with a water displacement lubricant (typically WD40), to prevent rust formation internal to the injector during return shipping, and customer receipt.
R) Injectors are now refitted with new filters, spacers, pintle caps, and o-rings, as applicable for the specific injector being tested.
S) Injectors are carefully packaged and readied for shipment to customer, with a full written test report.
T) An e-mail is sent to customer with a summary report of the testing.
U) To view the form used and the details provided for pre and post cleaning testing Click here
As you may notice, the cleaning and testing is exhaustive, and for a set of 12 injectors, on average, requires about 5 hours, to complete...excluding refitment on your rail, e-mails, writing reports, or preparation for re-shipment.
NOTE: Your injectors are tested at +/- 80 feet above MSL (mean sea level). Flow rates will vary at different altitudes. For an explanation of psi variations at altitude...have a look at this link CONVERSION
For Jaguar vehicle owners. With perhaps two exceptions, flow rate information for Jaguar injectors is proprietary between Jaguar Cars Ltd., and Bosch. The underlying reason is Jaguar Cars (now owned by Tata), wants you to obtain new injectors from your Jag dealer, as opposed to you substituting other injectors made by other injector manufacturers, or wanting you to know if your injectors are performing to factory specs. By withholding the flow rates, and other injector data, you are presumeably forced into a purchase from the dealer.
I have serviced thousands of injectors from Jaguar cars. Therefore, I have that information in my data. So, I know what they flow, and I know the other data. I know how your injectors are suppose to perform from the factory. It is easy (for me) to determine, after injector cleaning and service, if your injectors are within factory specs. Another reason, why you should allow me to test, clean, and service your injectors.
Should you have a question on your Jaguar injectors, or any other make/model engine injectors from any other manufacturer, please send me an E-MAIL
Jaguar Fuel Injector Service
14869 Yellow Water Lane
Jacksonville, Florida 32234
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This page was last updated on Tuesday, January 31, 2017.