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AUS Re-manufacturing Processes

The AUS Remanufacturing Process
AUS Injection offers a complete line quality remanufactured fuel injectors for
domestic and import applications. All fuel injectors are remanufactured at our
Arizona facility and are tested and date coded before packaging. (This minimizes
the possibility of defects)
All remanufactured fuel injectors we sell carry a 1 year replacement warranty
from date of installation. We date code every unit at the time of final testing, just
prior to delivery. This procedure assures the customer that the injector was flow
tested on the marked date, and gives AUS a reference date for any alleged

The Remanufacturing Process:
Not all injectors are the same! Therefore the remanufacturing process is
not the same for all injectors!
Our 14 years of experience allow us to determine the best process for the
type of injector to be remanufactured.

  • Multec Injectors: Additional reverse flow cleaning time
  • Bosch Nozzle type: Additional Ultrasonic cleaning time
  • Delphi, Nippon Denso,Bosch pencil style: Additional reverse flow cleaning time
  • TBI Injectors Disassembled and recalibrated

(An alternate core or a new part substitutes all part numbers that are known to
have external leaking problems, or intermittent flow due to poor original design.)
All injectors are electronically tested:
Coils are tested for correct electrical resistance and for coil weakness.
Good units are then disassembled (Micro filter, seals, pintle caps and plastic
spacer are removed.)

Internal Ultrasonic Cleaning:
Sets of 8 injectors are simultaneously cleaned in ultrasonic tanks specifically
designed to clean fuel injectors. The injectors are placed in the ultrasonic tank
with a cleaning solvent while they are electronically activated. The ultrasonic
waves are allowed into the fuel injectors to clean and remove all internal

External Cleaning:
Once the internal contaminants have been loosened up then the fuel injectors
are completely submerged in bigger tanks to complete the ultrasonic cleaning
internally and externally.

Back Flushing:
Once the injector has been cleaned ultrasonically, all units are individually back
flushed to remove the broken dirt particles. These particles can not be removed
thru the injection orifices so they are driven out thru the inlet of the injector.

Reverse Flow Pressure Cleaning:
(This extra step is very critical, especially on all GM Injectors). All injectors are
then mounted on the flow bench in an inverted position allowing them to reverse
flow at a considerable pressure. We run a high performance injector cleaning
solvent thru the injectors for 30 minutes, completing the cleaning process. This
process assures us that all dirt particles completely removed from the injector.
No other company performs this procedure.

Leak Test:
Injectors are now mounted on the flow bench in the correct position to begin the
testing procedures. We apply 60 PIS of pressure (more than a regular multi-port
fuel injection system) and maintain this pressure with no signal to the injectors for
30 seconds. This test is to ensure that there are no fuel leaks.

Spray Pattern Test:
The spray patter is then visually inspected applying pressure and holding the
injectors statically open for correct spray form (Spray pattern may be different in
some injectors).

To determine is any flow differences are caused by dirt blockage or
defective injector components we perform two additional measuring tests:

Static Flow Test:
The amount of fuel delivered by each injector is measured by holding the injector
continuously open at a constant pressured (normally 44 PSI / 3 BAR) for a
predetermined period of time). During this test if there is a flow difference of
more than 4% it is likely caused by dirt blockage since the injector components
(spring& coil) are not being utilized at this time.

Dynamic Flow Test:
The amount of fuel delivered by each injector is measured by activating the
injector at different pulse cycles and RPM¡¦S at a constant pressure (normally 44
PSI / 3 BAR) for a predetermined period of time. (This test better simulates actual
daily driving conditions). If the flow difference in this test is greater that the
difference of the static test this would indicate faulty injector components (spring
or coil).

Painting / Polishing:
Depending on the original manufacturer presentation, the injectors are either
painted or polished to give the best cosmetic appearance possible

New Components:
Injectors are now assembled with new replaceable components (Filter baskets,
pintle caps, O-rings and seals)

Final Tests:
A final test is now performed with all new components installed. The purpose of
this test is to make sure the filter basket; o-rings, seals and pintle caps are
positioned correctly and are not disturbing the flow or the spray pattern of the

Lubrication & Packaging:
Injectors are lubricated with special oil and protective caps are placed on both
ends to extend the shelf life assuring that when they are installed they will be in
optimum operating condition. Each injector is individually bag.

We guarantee our rebuilt injectors to be free of defects in material or
workmanship, under normal use and service for a period of 12 Months following
original installation. AUS Injection, Inc. obligation under this policy is limited to
the replacement of any part that is returned to AUS Injection Inc., freight prepaid
and which upon examination is found to be defective.

This limited warranty is in lieu of all other warranties, expressed or implied. And
all other obligations or liabilities on its part, AUS Injection Inc. neither assumes,
nor authorizes any other person to assume for it, any other liability in connection
with the sale of its products.
AUS Injection Inc, liability from all causes is limited to the value of the goods or
services sold or furnished. No other liability is expressed or implied.

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