Remanufacturing of Common Rail Delphi injectors - AutoNorma

How do we refurbish DELPHI injectors?

Each injector is disassembled for parts from the original production. All these components are then cleaned using an ultrasonic cleaner.

Fig: Cleaning of injector parts in the ultrasonic cleaner

The individual components are then examined under a microscope. No parts that do not match the quality of the new part will be selected. If some injector components can be reused, they are separated from the non-compliant parts and then machined. Non-conforming injector parts are replaced with new parts from Delphi.

The original Delphi valve, which suffers the most from damage at the Delphi manufacturer, is always replaced with a new valve.

The injectors are assembled together using the manufacturer's specialized tools.

Another major problematic element is the injector end cap. These are damaged due to a poorly designed injection pump.

Delphi injector tip and valve

Once all the parts are in place, the injector is assembled by trained personnel.

At the test station, the injector is subjected to the following partial tests:

High pressure leak test with overflow measurement without injector control
Injection rate and overflow measurement at full load
Injection dose measurement at idle
Initial dose measurement
Measurement of dose increment characteristics as a function of increasing power
Injector response test - testing the delay from the actual signal to the actual opening of the injector nozzle
Fuel dissipation test
Coding, determine new C2i (16 characters) or C3i (20 characters) code for Delphi Common Rail injector

Exploring microscopic differences on individual injector parts

Everything is ready for the DELPHI injector assembly

Each injector is disassembled into primary production components. After that, all these components are cleaned using an ultrasonic cleaner.

Čištění dílů vstřikovače v ultrazvukové čističce

Obr: Cleaning the injector parts in an ultrasonic cleaner

Individual components are then examined under a microscope. No parts that do not match the quality of the new part will pass the selection. If some elements of the injector can be reused, they are separated from non-compliant parts and then machined. Unsatisfactory injector components are replaced with new components from Delphi.

The original Delphi valve, which suffers the most from damage, is always replaced by a new valve.

Obrazovka

The injectors are assembled together using the manufacturer's specialized tools

Měření

Another important problematic element is the injector tip. These are damaged due to a badly designed injection pump. 

VentilDelphi injector tip and valve

Once all components are in one place, the injector is assembled by trained personnel.

At the test station, the injector is subjected to the following subtests:

  • High pressure leak test with overflow measurement without injector control
  • Injection dose measurement and overflow at full load
  • Injection dose measurement at idle
  • Initial dose measurement
  • Measurement of dose increment in dependency of increasing performance
  • Injector Response Test - delay test from actual signal to actual injection nozzle opening
  • Fuel Dispersion Test
  • Coding, we specify a new C2i (16 characters) or C3i (20 characters) code for the Delphi Common Rail injector

Bádání mikroskopických rozdílů na jednotlivých dílech vstřikovače

Research of microscopic differences on individual parts of injector

Vše je nachystáno pro složení vstřikovače Bosch

Everything is prepared for the composition of the Delphi injector