Hello friends.I have peugeot 406 coupe remmaped by ECUEDIT and the car runs really great.I want some info help about injector corrections.Ussualy all injectors on hot engine have 0.2-1.3mm corections.The car runs fine , no smoke , no vibrations starts perfect.
Two days ago i decidet to remove all injectros and to apply a ceramique paste around them to be prepared one day they will come out easy.I took them out very easy with no problem.We cleaned the beds where they lie and changed the washer.I also removed the nozzles to clean them and test them that all holes are open.After that we put back nozzles and installed injectors.The car started , no smoke , no vibrations but there is some knocking under load not smooth as before and it knocks all the time.The injector corrections now are first -0.23 second -2.5 , third +4.0 fourth -2.5 before i installed the nozzles i put some thin oil to lubricate the nozzes for the first start.And also when cold engine and some time when hot the fuell pressure is playing like +- 20 to +-48bars on idle.Some times perfect and not playing -2+6 I think this is bad fuel pressure regulator.The main question is where did i get wrong and could this pressure regulator cause bad corrections on injectors.

Thanks :(

I have this video before i removed the injectors from the car.
And if i installed them in wrong order do i have to register the injector codes in the ecu or my system is not like this ?

https://www.youtube.com/watch?v=7peOxzH99QE

stanleybg wrote:Hello friends.I have peugeot 406 coupe remmaped by ECUEDIT and the car runs really great.I want some info help about injector corrections.Ussualy all injectors on hot engine have 0.2-1.3mm corections.The car runs fine , no smoke , no vibrations starts perfect.
Two days ago i decidet to remove all injectros and to apply a ceramique paste around them to be prepared one day they will come out easy.I took them out very easy with no problem.We cleaned the beds where they lie and changed the washer.I also removed the nozzles to clean them and test them that all holes are open.After that we put back nozzles and installed injectors.The car started , no smoke , no vibrations but there is some knocking under load not smooth as before and it knocks all the time.The injector corrections now are first -0.23 second -2.5 , third +4.0 fourth -2.5 before i installed the nozzles i put some thin oil to lubricate the nozzes for the first start.And also when cold engine and some time when hot the fuell pressure is playing like +- 20 to +-48bars on idle.Some times perfect and not playing -2+6 I think this is bad fuel pressure regulator.The main question is where did i get wrong and could this pressure regulator cause bad corrections on injectors.

Thanks :(

hi stanleybg,
you wanted to do good thing but very bad idea :( the main problem is that when you take apart the injector,
you can not put it back without very very high professional tools that measure all washers, spring forces, overflow, LL, VE, EM test points on the machines that cost few hundreds thasuand of EUR.

when you take apart the injector and put it back together force of tightening is not the same as before and distances
for moving parts is not the same any more as well as opening pressure that is for that injector by Bosch declaration 130bar - mechanical opening.

injector have a lot of mechanical specification that are precise in so crazy measures that can kill your correction for +-9 just bay taking back together the injector without calibration.
everything matters when opening and putting back the injector...

springs
washers
valves
nozzles
force of thigtening
holes
overflow value
state of the housing
state of the thread

it happens that before opening correction +-1 after work without measuring on machine +-9 and very bad sounds, engine can start to work not on all cylinders...
because of opening pressure can go to high and to late...and so on.

there are very little people here in Europe that work on injectors so deep that measure just all of the parts inside the injector and set it up
by the book and calibrate on machine by the book. to do that you need one full day for 4 injector to be done 100% perfect and with maximum flow just little bit
below the maximum - that gives best performance and low consumption and no smoke...

you wont believe it - new injectors are pretty poor calibrated, and are mostly set up at minimum...differences are pretty silly,
we almost always open new injectors and perform fine calibration.

here is one of my reports of injectors just to see.
you can take them out send it to me and we will calibrate it.

stanleybg wrote:I have this video before i removed the injectors from the car.
And if i installed them in wrong order do i have to register the injector codes in the ecu or my system is not like this ?

https://www.youtube.com/watch?v=7peOxzH99QE

order of those injectors does not matther.
those injectors have first generation coding by clasees ABC, XYZ, 123,
where ax1 means that injector is set up at minimum, by2 middle, cz3 maximum (gruppe),
this is set up in BSI.

so people can cheat little bit by putting set up Z 3 to 1 and BSI will think that there is injector with set up at minimum
and it will give even more fuel by using corrections for class 1.. and so on ;)

my previous post gives you an answer and it is impossible to solve it without calibrating it properly. :(

I did not open the upper part of the injector.Just the nozzle there is only pin in the nozzle and piston with sprink on upper part.I think this hard to calibrate thinks are on the upper valve whete the electric conector goes in or i am wrong ? :crazy: :cry:

stanleybg wrote:I did not open the upper part of the injector.Just the nozzle there is only pin in the nozzle and piston with sprink on upper part.I think this hard to calibrate thinks are on the upper valve whete the electric conector goes in or i am wrong ?

any injector opening requires screwing and by screwing it back you move parts,
tolerances are so small that can mean very big differences. upper part is even much much more sensitive.
corrections from -2 up to +2 are not bad for those injectors, everything over that is not OK.

did you put cuprum seals same thickness under the injectors,
and did you took of some material from head while cleaning, so that injectors comes closer to the piston?

No i did not removed any material , just clean with soft cloth , and installed new ОЕМ copper seals same OEM size.

stanleybg wrote:No i did not removed any material , just clean with soft cloth , and installed new ОЕМ copper seals same OEM size.

that's fine, because i had bad luck once and had to remove 1,5mm of material so i used 1,5mm thicker washer to maintain same "height"...
than only injector set up is not ok any more - why - something was already on the limit and when you took off lower part it was nothing
but enough to feel the difference probably.

when you wont need a car for few days you can take them out and send me. you can get them in 3-4days back,
i can check with my friend for his time - those are his machines.

And is there specific torque to tighten the nozzle to the injector and to tighten the injector to the head ? I have torque wrenches.I hoped month of may to go to peugeot country meeting and to have some drag race :)

stanleybg wrote:And is there specific torque to tighten the nozzle to the injector and to tighten the injector to the head ? I have torque wrenches.I hoped month of may to go to peugeot country meeting and to have some drag race :)

yes,
there is documentation for injectors for every thigten torque and all tolerances for every spring, washer and the rest,
here is little print out for your injector - attachment.

you can give it a try to use procedure.
i also checked your video right now the behaviour that is going on is related also to the precontrol valve
on the high pressure pump in most cases only rubber seal and one little plastic part has to be changed, check here, it costs 5€:
post2039#p2039