Process
Over 25 years’ experience servicing, rebuilding & repairing diesel fuel injection systems and being associated with world renowned companies like Bosch, Delphi, Denso, Continental we have mastered the process of repairing fuel systems and turbochargers. We follow a full circle of fault diagnosis, identification and rectification with the help world class test equipment.
We believe learning is constant and train ourselves to improve the process and given out better quality constantly.
Diesel Injection Systems
Visual Test
Fuel injection component is looked for physical damages such as cracks , heavy corrosion , welding spots , overheating and completeness.
Electrical Test
The fuel injection component is tested for electrical tests like insulation , resistance , dynamic resistance , capacitance .
Flushing & Pre Testing
Fuel system is tested at low RPM to remove diesel from inside and see and study the condition of the same . Also this pre testing educates on level of the wear and tear of the component.
Cleaning
Ultrasonic cleaning of fuel system components , followed by air drying and then washing under clean diesel.
Estimation
Repair pricing is shared with the customer for approval.
Disassembling
Disassembly of the fuel system for parts and components with microscopic verification of defects.
Parts Replacement
Replacement of elements such as element , delivery valve , control valve , nozzle , seal rings, shims , balls , cap nuts , inlet connectors , shafts , supply pump , imv that have been damaged, if necessary, we replace or remanufacture the components
Assembly
New components along with washed okay components are assembled as per OE specifications.
Stage 3 Repair
Specialized tools are used to set fuel doses and set injection timing.
Disassembling
Packaging
All primary packaging is kept in mind to prevent corrosion and the safe packaging is done for long distance logistics.
Pre Packaging
Systems are verified for completeness and extra external parts received are fitted back.
Calibration
Fuel system is simulated on test bench to verify , set performance parameters such full load delivery , idle delivery , emissions delivery , starting delivery , fuel losses and leakages. Common rail injectors are also coded as per specifications.
Turbo Chargers
Visual Test
Turbocharger is looked for physical damages such as cracks , heavy corrosion , welding spots , overheating and completeness.
Wastegate Test
Actuator is tested for pneumatic leakages , short circuit , driver board performance , punctured diaphragm
Disassembling
Disassembly of the turbocharger for parts and components with microscopic verification of defects.
Sand Blasting
Sand is blasted against he surface to remove all debris and carbon to give new like finish.
Estimation
Repair pricing is shared with the customer for approval.
Vane Assy Testing
To verify free movement of vane assembly along with verifying angle of the fins.
Cleaning
Ultrasonic cleaning of turbocharger components
Parts Replacement
Replacement of elements such as bearings, sealing rings, etc. and parts of the rotating system that have been damaged, if necessary, we replace or remanufacture other turbine components such as variable geometry, pneumatic or electronic actuator, etc.
Assembly
CHRA are assembled as per OE specifications
Disassembling
Packaging
The product is packed in safe packaging , along with priming injection and necessary gaskets.
Calibration
Dynamic multipoint flow and pressure test on cimat turbotest machine, study of turbocharger compression characteristics.
Core Balancing
Inspecting the rotating turbocharger components on a balancing device, which records unbalance even at speeds of 200k. / min. This measurement enables the observation and subsequent reduction of vibration at all harmonics.
