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

VT.jpg

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 . 

CR E Test.jpg

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.

Leak Test.jpg

Cleaning

Cleaning.jpg

Ultrasonic cleaning of fuel system components , followed by air drying and then washing under clean diesel.

Estimation

Estimation.jpg

Repair pricing is shared with the customer for approval.

Disassembling

Disassembly of the fuel system for parts and components with microscopic verification of defects.

21.jpg

Parts Replacement

New Parts.jpg

Replacement of elements such as element , delivery valve , control valve , nozzle , seal ring s, 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.

Assembly.jpg

Stage 3 Repair

Specialized tools are used to set fuel doses and set injection timing.

Stage 3.jpg

Disassembling

Packaging

Ready.jpg

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.

Pre Packaging.jpg

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.

Calibration.jpg

Turbo Chargers

Visual Test

Visual Test.jpg

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 

Wastegate.jpg

Disassembling

Disassembly of the turbocharger for parts and components with microscopic verification of defects.

Inspection.jpg

Sand Blasting

Shot Blasting.jpg

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. 

Vane Assy.jpg

Cleaning

Ultrasonic.jpg

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.

1000x1000_edited.jpg

Assembly

CHRA are assembled as per OE specifications

CHRA.jpg

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.

Calibration.jpg
C.jpg

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.

CHRA Balanacing.jpg