PRACTICAL REPORT

INJECTOR TESTER AND CLEANER

Lecturer
Mr. Asrul Syaharani Bin Yusof

By
Name ID
1. Mohd Zahir Bin Abdullah 50216117072
2. Mohd Faizal Bin Sadimin 50216117059
3. Shahizan Bin Sahid 50216117075

Subject
ENGINE PERFORMANCE ENHANCEMENT
FVB 41630

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Table of Contents
1.0 GROUP MEMBERS....................................................................................................................

2.0 INTRODUCTION.........................................................................................................................

3.0 INJECTOR TESTING AND CLEANING PROCEDURE..............................................................

3.1 Setting Up the injector tester equipment.....................................................................................

3.2 Gauge Layout..........................................................................................................................

3.2.2 Pressure Control Knob.............................................................................................................

3.2.3 Pressure Release Knob...........................................................................................................

4.0 STANDARD INJECTOR TESTING.............................................................................................

5.0 LEAK TEST..................................................................................................................................

6.0 SPRAY PATTERN TEST............................................................................................................

7.0 FLOW TEST.................................................................................................................................

8.0 CLEANING INJECTORS...............................................................................................................

8.1 Servicing Injectors.........................................................................................................................

8.1.1 Handle with extreme care. Dropping an injector with the pintle exposed or the filter basket
removed, could caused damage to the injector..............................................................................
9.0 FUEL PRESSURE MEASURING PROSEDURE......................................................................

10.0 CALCULATION HORSEPOWER (HP), NEW INJECTOR FLOW RATE, NEW

HORSEPOWER (HP), INJECTOR DUTY CYCLE (IDC) CYCLE TIME BASED ON

RECORDED RPM.................................................................................................................

11.0 CONCLUSION........................................................................................................................

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1.0 GROUP MEMBERS

MOHD ZAHIR BIN

ABDULLAH
RACING LEADER

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 SHAHIZAN BIN SAHID MOHD FAIZAL BIN
RACING FORMEN SADIMIN
RACING DRIVER

2.0 INTRODUCTION

Since it can take well over an hour to access and evaluate fuel injectors, injector
maintenance is done by time and mileage intervals rather than from direct inspection. We
recommend cleaning fuel injectors at least every 36 months or 45,000 miles.
In the subject of this performance of engine, we will do the practical work of cleaning the
fuel injector nozzle using the injector machine cleaner model ASNU.
In the typical gasoline fuel-injection system, an electric fuel pump provides a specified fuel
flow at the required system pressure to one or more fuel-injection valves, or fuel injectors.
The gasoline fuel injector is an electromagnetic (solenoid-operated) or mechanical device
used to direct delivery of or to meter pressurized fuel, or both. A fuel-pressure regulator
maintains a controlled fuel pressure at each injector, or a controlled differential pressure
across the injector.

The fuel injector is the last stop for fuel in engine before it goes boom inside the combustion
chamber. It is basically an electrically operated gate that opens just long enough to meter
the perfect amount of fuel to run the engine. On one end of the gate is the cylinder where
the gas is ignited, and on the other end is a whole bunch of gas under high pressure. When
ECM (connected to a Mass Airflow Meter or MAF to take measurements) sends an
electrical impulse to the injector, it opens the gate for an short burst of fuel.

The injection nozzles are contaminated with carbons throughout the prolonged usage of the
impurities petrol. This can lead to declining engine performance. One of the methods to

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 restore engine performance is doing injector cleaning.

Fuel injector symptoms for bad, faulty, dirty, clogged, or leaking injectors are :

 Starting issues.
 Poor idle.
 Failed emissions.
 Poor Performance.
 Engine does not reach full RPM.
 Increased fuel consumption.
 Rough engine performance.
 Surging and bucking under various throttle loads.

3.0 INJECTOR TESTING AND CLEANING PROCEDURE

3.1 Setting Up the injector tester equipment

1. Connect the Injector harness

2. Connect power supply

3.2 Gauge Layout

3.2.1 Pressure Gauge: Pressure gauge indicates the system

pressure testing The gauge measure 0 – 10bar / 0 – 150 psi

3.2.2 Pressure Control Knob

Turning this knob can be used for different reason dependent and turning it anti-clockwise will
decrease pressure.

3.2.3 Pressure Release Knob

This pressure can be used for different reasons dependent upon if the machine is running or not,
as follow:

Machine Not Running: By pulling the knob out, the system pressure is release i.e. used
before disconnecting any part of the fluid system such as removing the fluid hose or
removing injectors.

Machine Running: Whilst the machine is running the knob can be momentarily pressed to
increase the fuel pressure to force flush the injectors (once this knob is releasing the
system pressure returns to its previous setting). Likewise, the knob can be momentarily
pulled to decrease the pressure.

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4.0 STANDARD INJECTOR TESTING
4.1 General

1. Prepare the injector

2. Use the capping-off nuts provided to block all unused outlet port on the fuel rail.
3. Select appropriate coupling.
4. Lubricate the “O”-ring, and gently push injector into the coupling and onto fuel rail.
5. Finger tighten the fuel rail bolts.

6. Place the fuel rail assembly I the locating notched above display window.
7. Ensure fluid pressure is fully release by pulling out the

knob.

Pressure gauge should be zero.

8. Connect the fluid hose to the fuel rail.

9. Connect the wiring harness to the injector

The numbers on the individual wires should be kept in a numerical order so comparative results
can be easily made before and after cleaning

10. Select function 1. PRIME INJECTOR. Press the GREEN GO button and the pump will run, turn
the Control Pressure Knob to set the system pressure. To set system pressure for type of injector
being tested (refer to manufacturer’s data)

L-JETRONIC type injector working pressure may vary from 1.8 to 3.0 bar. Recommended testing
pressure is 2.5 bar.

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5.0 LEAK TEST
1. Place fuel rail assembly above display window.
2. Select function 2. LEAK TEST

Press GREEN GO button and examine the injector for leaks. After 30 second leak test cycle
has finished, do not release the system pressure.

3. Blow dry the injector and allow the injector to sit in the fluid rail, at rest pressure, for a further
30 second.
4. Check injector for leaks or dribbling.
5. Repeat the leak test at a pressure of 1 bar higher than normal and again at 1 bar lower than
normal system pressure.

This will check injector seal properly at various pressure.

6. Record the result.

Injector 1 Injector 2 Injector 3 Injector 4

No leak No leak No leak No leak

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6.0 SPRAY PATTERN TEST
1. Place fuel rail assembly above display window.
2. Select function 3. FLOW - MODE 1

Press GREEN GO button and the system will now flow for 30 seconds.

Examine the spray pattern for regularity, injector spray and performance.

3. Using LEFT/RIGHT button, select different mode (various opening times and speed) over a 30
seconds time period.

Examine the spray pattern for regularity, injector spray and performance.

4. Grade the spray pattern and record the result.

Injector 1 Injector 2 Injector 3 Injector 4

pintle pintle pintle pintle

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7.0 FLOW TEST
1. Place fuel rail assembly above floor rack measuring cylinders.
2. Select function 3. FLOW - MODE 1

Press GREEN GO button and the system will now flow for 30 seconds.

NOTE if the amount of fluid in the tubes is less than 50ml at the end of the 30 second flow
cycle, repeat the flow cycle to enhance the differences of volumes in the test tubes.

3. Record the spray volumes.

4. After use, the measuring cylinders should be emptied into the fluid tank.
a. Place the fluid rail above the display windows. Ensure that the injector harness is clear of
the flow rack before emptying
b. First, REMOVE THE TANK COVER LID.
c. Emptying the flow rack is achieved by swiftly lifting the floe rack toward the fluid tank.

5. Fill up the table below for your result.

Mode: 1
Seconds: 30 ms
Volume: 104 ml
ms RPM Duty Cycle % Pulse Count
3.00 1666 50/50 %

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8.0 CLEANING INJECTORS
1. Ensure that the fluid pressure is fully release by pulling out KNOB on the front panel, underneath
the pressure gauge.

Do not alter the pressure setting.

2. Uncouple the fluid pipe and injectors from the fluid rail without disconnecting the wiring harness.
3. Before placing the injector into the ultrasonic cleaning bath, hold the injector over a waste
container and press the PULSE INJECTOR button whilst blowing through each injector using
clean filtered low pressure compressed air (1-1.5 bar) to remove any FLOW TEST fluid remaining
inside the injector.
NEVER ALLOW THE ALTRASONINC AND INJECTOR TEST FLUID TO MIX.

4. Check the ultrasonic cleaning fluid level is just above the level sensor.

If too low, waring buzzer will sound and cleaning function will not function.

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 8.1 Servicing Injectors

NOTE: It is important that the injectors are tested in the same condition BEFORE and AFTER
cleaning to obtain comparable results.

1. Remove fuel injection hose from injector (if necessary).

2. Wash the complete injector to remove any external debris using detergent agent.
3. Using the filter extraction tool provided, remove the injector filter basket.
4. Inspect the inlet of the injector for CORROSION, RUST or

DEBRIS.

Remove the bottom ‘O’-ring before removing the pintle cap.

8.1.1 Handle with extreme care. Dropping an injector with the pintle exposed or the filter basket removed,
could caused damage to the injector.
5. CAREFULLY remove the pintle insulator cap using removal tool.
6. With the injector still connected to the main wiring harness, place injectors into holes in the
ultrasonic cleaning cradle in any of the eight-location available.
7. Select function CLEAN - MODE 4 (AUTOMATIC)

Press GREEN GO button and the system will now flow for 10 minutes.

8. Observe the process and record any finding in the result.

Injector 1 Injector 2 Injector 3 Injector 4

Browning liquid crystal liquid melt Browning liquid crystal liquid melt
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 melt out out melt out out

9.0 FUEL PRESSURE MEASURING PROSEDURE

1. Prepare fuel pressure gauge set box.

2. Connect the fuel line with T-adapter and
connect pressure the gauge.
3. Start the engine and let it idle
Observe the fuel pressure gauge while the
engine runs and after shutting off the
engine. Fuel pressure should hold to specs,
while the engine is running, and after
turning off the engine.
Compare readings to specification in repair
manual.
 If gauge reading is lower than the
specification while the engine is running
(pressure goes down quickly or after a
few minutes, or doesn't build up), you'll
need to check the fuel pump (failing to
pump at the adequate rate), fuel filter
(restricted or clogged), or the anti-drain
valve (failed—draining fuel back into the
fuel tank) on the fuel pump assembly.
 If fuel pressure begins to drop soon after
shutting off the engine, probably have a
leaking injector, a leaking anti-drain
valve in the fuel pump assembly.
 When detect low pressure, and not
changed the fuel filter in more than a
year (or at the interval suggested in car
owner's manual), replace the filter, and
repeat the test again. A clogged or
partially clogged filter may be problem.

Report :

Condition Fuel Pressure

Engine Off 0
Engine Idle (800
60 psi
rpm)
Engine Ramp Up 60 psi
Engine Shutdown 40 psi

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 60 psi at running
Specification
condition

10.0 CALCULATION HORSEPOWER (HP), NEW INJECTOR FLOW RATE, NEW

HORSEPOWER (HP), INJECTOR DUTY CYCLE (IDC) CYCLE TIME BASED ON
RECORDED RPM.

Crank shaft sensor waveform :

Cycle = 78.87 ms, 236.1 ms = 157.23

ms (b)

Injector No. 1 waveform :

Inj = 85.9 ms , 89.14 ms = 3.24 ms (a)

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 Injector Flow :

208 cc/min = 19.8 lb/hr

Tachometer :

850 rpm

Fuel pressure :

60 psi

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Flow rate = injector size cc/min
IDC = Injector Duty Cycle
BSFC = Brake Specific Force Consumption

BSFC NA = 0.5 , I/F = 0.65

Solution :

Horse Power = Injector Size x IDC

BSFC

b
IDC ¿ x 100
a+b

a=
duration of injector
b = 1 cycle of engine

= 157.23 ms – 3.24 ms x 100

157.23 ms

= 97.93

= 98 % = 2% = 0.02

HP = 19.8 x 0.02 = 0.792 (4) = 3.16 HP

0.5

new pressure
New Injector Flow Rate = √ x old flow rate
old pressure

90
=√ x 19.8
60

= 24.24 lb/hr
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HP = 24.24 x 0.02 = 0.97 (4)
0.5

= 3.88 HP > New Horse Power

11.0 CONCLUSION

In this instance, we find that the horsepower of an engine is influenced by the injector. The
injectors on an engine affect the output power from the fuel combustion in engine cylinder. The
injector needs to be serviced and tested for fuel refinement as soon as it receives a signal from
the ECM. The fuel pressure transmitted to the injectors must also be maintained and in
accordance with the engine specifications. Horsepower calculations can be done with theoretical
formulas as well as obtaining real horsepower using a dynamometer.

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