We are a full service gasoline fuel injector testing and repair facility. We refurbish injectors back to their original state by cleaning them in a heated ultrasonic bath. This process is verified with before and after test results. Below are some more detailed descriptions of the steps we take to make your injectors operate like new again.
Upon receiving your injectors, we perform a visual inspection. Your injectors are checked for any damage to the body or pintle that may render it dead. We check the electrical pins for looseness and corrosion, the plastic body for cracking, and the pintle cap for physical damage. If we see any damage that can not be repaired the injector will be excluded from the following tests and you will not be charged for that particular injector. In this picture you can see some examples of injectors that would be rejected for further testing.
The next step in our testing process is the spray pattern test. This test is a visual confirmation of the injectors spray pattern. Depending on the style of injector nozzle many different spray patterns are possible. Regardless of spray pattern style, we look for uniform spray patterns with no abnormalities. During this test the injectors can fired at multiple intervals from 200 RPM (cranking) all the way through 10,000 RPM, as well as varied pulse widths from 3ms to 12ms. This test is always important, but it is especially crucial on GDI style injectors. If you have any specific concerns about how your motor is running, we can test for these at this point. For example if your motor hesitates at 2500 RPM while accelerating, we can use that information to our advantage and look closer at that specific RPM range.
After we have performed the initial visual inspection, the next test we perform is an inductance test. This test is measuring the actual electromagnetic force that is created by the injectors internal electrical coil. The unit of measure we are looking at is called a millihenry, or mH. It is a much more accurate way of testing the injector's internal coil than a basic resistance test. In addition the test is run while the injector is operational, so we can also watch any change in the inductance as the coil heats up through operation.
The final stage of testing, before we move onto cleaning is the flow tests. There are two flow tests that we perform. The first is a static flow test. This test holds each injector wide open for a set amount of time. The results are compared side by side with the other injectors from the same motor. The data collected from the static test tells us the maximum flow each injector can possibly put out. The next test is the dynamic flow test. This test cycles though various stages of engine operation, from cranking all the way through 5000 RPM. The RPM ranges are run at differing pulse widths from 3ms to 12ms, to accurately simulate real-world driving conditions. This test is helpful in giving us a inside look at the amount of fuel delivered during normal car operation.
Once all of the initial tests have been performed and the results recorded, we move onto the cleaning process. The first steps is to clean off any dirt or debris from the exterior surface of the injectors. This includes removing the paint from painted metal body injectors. After the injectors have been cleaned externally, we remove the internal filter screens from the injectors, carefully taking note of the debris present in each filter. Your injectors are now ready to be placed in the ultrasonic cleaning bath. The bath we use is heated to better help break down any stuck fuel deposits. While the injectors are in the bath, filled with specialized chemicals designed to break down carbon and fuel deposits, they are cycled to open and close the pintle. This cycling back-flushes, any deposits or debris from inside the injector back through the inlet of the injector. This process is repeated until we are satisfied that the injectors have been properly cleaned.
This is the final stop your injectors take before being returned to you. The previous tests, including spray, static flow, dynamic flow, and inductance tests are repeated. These tests are all ran at the same exact fuel pressure as previously to ensure accuracy. The results from these tests are compared to the previous tests and assessed. If there are any injectors that still fail the tests they are noted and tagged separately from the rest. The injectors now have their o-rings, spacers and seals replaced with new components. At your request we can return your old seals and o-rings with the injectors as well. Now the injectors are ready to be boxed up and returned to you, along with your testing results!