Diesel Injector Power Upgrade FAQs
→ Hammer Mod
This is the "hammer mod" if you have any questions please contact us at email@example.com
→ How different do TDI VE Injectors flow?
This is the test results of various nozzle flow rates showing the differance in deliverd quantity.
This has been done useing the most accurate testing method as all nozzles were tested useing the same "on engine" paramiters.
Please note that this information remains the property of United Diesel Fuel Injection Services Ltd.
→ PD 8V Nozzles, how do they compare?
This is an updated PD 8V Nozzle flow comparison chart. The results are the fuel delivers from each nozzle tested in the same injector and using the same test process.
There seems to be a miss conception about flow rates and percentages, for example you will see that the Firad +80% does not flow 80% more fuel than a stock nozzle
Stock 150 Bhp Bosch OEM nozzles delivers 23.8 Cms, with the same test the Firad +80% delivers 32.2 Cms which is a 37% increase in fuel.
I believe that some manufactures use the percentage to represent a hole size measurement but they all keep the manufacturing process to them selves so we might never know. The important thing for me is the end result of what the nozzle and injector body is capable of delivering.
It is more important to measure delivery of the complete injector as it will be a true reflection of it performance in the engine.
The chart is in the file download/
→ PD and VE injectors, how do you do them?
When enquiring about injector nozzle replacement, either standard or high performance or the supply of service exchange units it is important that you deal with a company that has the experience, knowledge and equipment to do the job correctly.
→ Performance injectors, my mapper wants to know what my injectors deliver.
We are pleased to be able to offer a custom “Injector Mapping Chart” for common rail injectors. This is especially helpful to any tuner who is in the process of remapping a modified vehicle. Whether there has been a bigger turbo, higher flowing injectors or a larger inter-cooler fitted, by being able to see what fuel deliverers are produced will allow for a more accurate and effective tune allowing for optimum performance.
The “Injector Mapping Chart” is totally custom so we can add or alter parameters to suit your needs. We are also able to compare delivers from stock and performance injectors so that the increases can be used to match other performance enhancing products.
Should you wish to know more please do not hesitate to contact us.
→ VE two stage injectors, how do you set them up?
The set-up of a two stage injector is very important to get optimum performance from your vehicle. If it is not set up correctly it can restrict the mount of fuel delivered on the other hand it can dump too much fuel in causing black smoke.
The nozzle choice is also important but we will cover nozzle sizes in a differant FAQ.
The set up is all to do with NOP1 and NOP2 (nozzle opening pressure) NOP1 is easy enough to do as this can be done on a standard pop tester.
Nozzle Opening Pressure (NOP2) cannot be detected by measuring only pressure or only flow. Similarly injected delivery alone does not give an indication of NOP2.
Want to get more technical? have a look at our download.
→ What is a PD injector upgrade and how is the injector calibrated?
Unit injectors incorporate the nozzle assembly and a built in high pressure pump producing injection pressure of up to 2000 Bar. Similar to that of a common rail system but with the fuel rail chamber only needing a supply pressure of 2.0 Bar.
→ What is a VE injector power upgrade and how is the flow checked?
Using the 2 Stagemaster's flow mapping ability we are able to map the flow characteristics of each nozzle prior to fitting in the injector. This test is performed on the nozzles prior to installation to insure that every nozzle performs exactly to specification. We are able to evaluate delivery rate, peak delivery volume as well as flow through the flow range.
→ What is the Process for Nozzle Set-up and Calibration on a PD Unit Injector?
Nozzle Set-up and Calibration, PD Unit Injectors.
Disassembly, Inspection and Nozzle Mounting for PD Injectors.
Unit injectors incorporate the nozzle assembly and a built in high pressure pump producing injection pressure of up to 2000 Bar. Similar to that of a common rail system but with the fuel “rail” chamber only needing a supply pressure of 2.0 Bar. The PD system greatly increases the precision and control over combustion when compared with older fuel injection systems. Specialist equipment is needed just to be able to strip and inspect the injectors due to the complex set up of internal locating plates and pins. With every service we provide a complete strip and inspection of the injector. Parts are then ultra sonically cleaned and worn parts replaced. A nozzle of choice is then assembled into the nozzle assembly holder and NOP1 is setup to insure the most precise calibration of the injector. We are able to set the PD injectors back to OEM specifications or, for custom or race applications, we can provide a custom pressure setup for your specifications.
Testing and Calibration.
The complete injector is then reassembled and mounted into the 555-2N Injector-Pump System Cam Box and run on our test bench connected to the 555- 24LX/EVO Simulator. The following areas of the injector are tested,
- Effective Injection Time in ms
- Nominal and Effective start of injection
- Nominal and Effective end of injection
- Current peak absorbed by the electrical solenoid and error message if value is exceeded
- Peripheral Speed of drive shaft whilst pumping
- Test Fluid Temperature measures at the Nozzle Outlet with a maximum protection value
- Visualization of “0” setting for both Cam and the Rotation Mode
- Atomization characteristics at Start Of Injection
Once the injector has passed either OEM or custom setting specifications the injector is marked with its unique identification number. A performance printout can be supplied on request. All injectors supplied will have a set of new fitment seals and the necessary washers.
→ What were the test conditions regarding the PD body flow tests?
The same DSSR 130+ nozzle was used in the 3 PD bodies. NOP 1 (nozzle opening pressure) was set to 300 Bar. The stock bodies were left as is and our standard test procedure was followed. The results have been documented as "test results for PD body flow rates"
Testing and Calibration.
The complete injector was then reassembled and mounted into the 555-2N Injector-Pump System Cam Box and run on our test bench connected to the 555- 24LX/EVO Simulator. The following areas of the injector are tested,
- Effective Injection Time in ms.
- Nominal and Effective start of injection.
- Nominal and Effective end of injection.
- Current peak absorbed by the electrical solenoid and error message if value is exceeded.
- Peripheral Speed of drive shaft whilst pumping.
- Test Fluid Temperature measures at the Nozzle Outlet with a maximum protection value.
- Visualization of “0” setting for both Cam and the Rotation Mode.
- Atomization characteristics at Start Of Injection.
Probably what will be more relavent is how we achieved the fuel specs.
Low Delivery - Cm3 Fuel delivery x 200 strokes at 300 RPM bench speed.
Full Load Delivery - Cm3 Fuel delivery x 200 strokes at 600 RPM bench speed.
Please see the attached document for the full test plan