Understanding injector assembly, calibration, and test data is important for tuners and the end user as well. Small changes in parameters can effect an injectors output and running characteristics. This page is to help explain more about what we do, why, and how - to a limited extent.
Assembly: Common rail injectors are extremely sensitive to dust, dirt and the equivalent during the assembly process. Clean rooms are not only a good idea, but certainly a requirement for the best results. With clearances measured in microns, even a small piece of lint can cause the set-up process to fail. This same lint particle can actually tuck away inside the injector and make its way to a critical area after the measuring process. We have developed some mechanisms to deal with these types of issues over the years. Also, wetted parts (assembled with test oil) or dry parts will have differing values, so it is important to appreciate the changes this can have while working up an injector. Multiple measurements take place during injector work up and each measurement needs to be taken more than one time and with multiple, noted as good, gauges. 99% of common rail injector functionality is determined during assembly! When building injectors, a test bench is only to verify the work you did. Test bench data can sometimes show an injector as good, but the injector internal values can be incorrect.
Calibration: This is predominantly done during the assembly and work up side of things, but calibration changes take place while the injector is being bench tested. As the injector delivery is measured, adjustment is sometimes needed to obtain the desired fueling volume. Changing pintle lift or solenoid air gap is a good example. Mounting and dis-mounting the injectors from the test bench during the calibration phase is common.
Test Data: Once the calibration is complete and the injector set is running as designed, we record some injector set-up values and test data. This information can help a tuner better create a tune file for your specific vehicle.