Injectors are very complicated,
they are built at the limits of manufacturing and have higher requirements in durability as every other part of a modern diesel engine. Bosch has designed its injectors to make billions of injection cycles over their lifetime. Therefore they have responded to a lot of challenges such as: caviation erosion, tribological stress, particle erosion, functional behaviour and so on. They really are a master piece of European engineering.
Every adjustment parameter,
every single piece (even the smallest) inside the injector, has its own function to meet all these challenges. We believe we are the first company modifying injectors that really understands how the injector works and how to get the maximum output in performance without harming the durability. So we are the only supplier capable of improving the nozzles, as well as the internals of the injector, essential for getting maximum power on racing applications.
Each injector set, gets tested
at its full pressure range with our special test program, which contains single injection test points like full load, low idle, pilot and post injection and complete injection quantity mappings over energizing time at low, medium and full system pressure (250, 1000, 1600bar). We also have the ability to measure the injection rate at the single test points. The fuel flow of each single injector set is calibrated and matched to a flow tolerance within 2% at full load point. Every delivered injector set contains a certification of its functional testing results. We have yet to see a modified injector nozzle,(other than our own) that maintains a correct spray angle. We’ve also never seen a nozzle with consistent hole diameter or shape.
Performance diagram of MY4.5 Stage 1 Injector with and without additional injector modification
Dynoplot of MY4.5 Stage 1 with and without injectorupgrade: download pdf
Nozzles: We only deliver nozzles with the newest design and reliability features. The nozzle holes are manufactured with an EDM process. Each nozzle is hydro erosive rounded to the exact flow value.
Injectors: BBI is the first injection modifying company who is able to change the complete injector setup to get better engine response and great performance at high rpm. We are the first ones not only offering a higher nozzle flow.
Testing: We only deliver fully tested injectors, meeting tight tolerance to ensure our own demands in quality. Each Injector gets tested at single test points; complete injection quantity maps up to system pressure (1600/1800bar) and shot/shot spread. For every injector set we hand out a test report sheet for the customer to be able to control our delivered quality.
Data sheet with complete mapping attached to each set of injectors: download.pdf