All About Injectors
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Logistics Pro
Joined: Oct 2008
Posts: 4,818
Likes: 1
From: Avilla, IN
All About Injectors
Let's talk about the science of Power Stroke injectors.
How do they work?
What is changed when they are modified?
ETC?
I know most of us know the basics, but lets get all the info in one thread
from the simple stuff to the complex theories that make these things work.
How do they work?
What is changed when they are modified?
ETC?
I know most of us know the basics, but lets get all the info in one thread
from the simple stuff to the complex theories that make these things work.
Elder User
Joined: Dec 2004
Posts: 891
Likes: 1
From: Toulon,Il.
First I am ready to be corrected if any info is wrong.
A PSD injector is a HUEI system inj. Hydraulic Unit Electric Injector.Basicly it is electric control over hydraulic pressure used to operate the flow of fuel into the combustion chamber.Which is referred to as "Direct Injection",the fuel is shot directly into the cylinder. The computer tells the inj to fire thru an electric signal applied to the solenoid,which is a strong magnet.When this magnet is energized it pulls up on an armature plate that is connected to a poppet valve. When the poppet valve is open engine oil is allowed at high pressure from the HPOP into a cavity above the powerpiston.This power piston is what holds the fuel to go into the cylinder.When the HPOP oil flows into the inj at about 2500psi it forces the fuel thru the injector nozzles into the cylinder.
The differences in the injectors are flow rates and "singles" or "splitshots".Singles are used in 94.5-97 trucks these shot the fuel in with one "Single" shot. The "Splits" shot an initaul smaller shot- known as a pilot shot- into the cylinder to start a precombustion before the big primary shot comes in.These were used from 97-03,the 97s were in "Cali" trucks or California spec.The primary reasons for the splits was emission related,but they also run a bit quieter. The physical differences are in the plunger in the lower half of the inj. If you look at a plunger from a split(AB,AD codes) it has about 5 holes in the bottom of it.I believe this is to relieve alittle of the initaul pressure creating a momentary smaller shot of fuel. The upper halves of the injectors are the same with the exception of the powerpiston.AA flow about 90cc of fuel,ABs 120cc,ADs 140cc.
When you build a set of Stage1s your are changing or modifing the powerpiston to flow 160cc. For Stage2s you also change the nozzles to flow 50 percent more.
Thats where my knowledge ends. There are bigger modifications that guys do, others will know more.
A PSD injector is a HUEI system inj. Hydraulic Unit Electric Injector.Basicly it is electric control over hydraulic pressure used to operate the flow of fuel into the combustion chamber.Which is referred to as "Direct Injection",the fuel is shot directly into the cylinder. The computer tells the inj to fire thru an electric signal applied to the solenoid,which is a strong magnet.When this magnet is energized it pulls up on an armature plate that is connected to a poppet valve. When the poppet valve is open engine oil is allowed at high pressure from the HPOP into a cavity above the powerpiston.This power piston is what holds the fuel to go into the cylinder.When the HPOP oil flows into the inj at about 2500psi it forces the fuel thru the injector nozzles into the cylinder.
The differences in the injectors are flow rates and "singles" or "splitshots".Singles are used in 94.5-97 trucks these shot the fuel in with one "Single" shot. The "Splits" shot an initaul smaller shot- known as a pilot shot- into the cylinder to start a precombustion before the big primary shot comes in.These were used from 97-03,the 97s were in "Cali" trucks or California spec.The primary reasons for the splits was emission related,but they also run a bit quieter. The physical differences are in the plunger in the lower half of the inj. If you look at a plunger from a split(AB,AD codes) it has about 5 holes in the bottom of it.I believe this is to relieve alittle of the initaul pressure creating a momentary smaller shot of fuel. The upper halves of the injectors are the same with the exception of the powerpiston.AA flow about 90cc of fuel,ABs 120cc,ADs 140cc.
When you build a set of Stage1s your are changing or modifing the powerpiston to flow 160cc. For Stage2s you also change the nozzles to flow 50 percent more.
Thats where my knowledge ends. There are bigger modifications that guys do, others will know more.
Hotshot
Joined: Jun 2007
Posts: 10,008
Likes: 7
From: Austin, TX
ok, the "power piston" fuelman is talking about is the intensifier piston. when upgrading the injectors the intensifier piston will be machined down to allow more fuel in. also stage 2 nozzles flow 80% more fuel. other than that everything else was correct that he said. now when changing to hybrids there are several other mods made to the injector to allow it to flow more fuel while using less oil. one mod is different plungers and barrels i believe. long story short, a set of 238cc/80% hybrid injectors will take LESS oil to run than my 160cc/80% injectors will. If you wanna read quite a bit on injectors check out this thread from PSN-- Uniform Injectors Standards - Powerstroke Nation
21 pages there, but probably only like 10 were good and technical. the rest was ppl complaining or something. haha. Basically with the little injectors there isn't too much modding they do, but when you start getting larger like 300cc and up then there are internal mods to the fuel and oil sides to allow them to fill and empty faster. such as the 455cc fire hoses w/ 400% nozzles. they empty FAST!!
Since the HEUI injector is unable to create the injection pressure of the common rails or even the VP44 trucks, we have to settle with volume of fuel over atomization to get the HIGH hp numbers from them without blowing them to pieces. now since we don't have that injection pressure/atomization that also means we have to use a larger turbo than should really be neccessary(instead of a 72mm getting us 650hp or so we are using a 76mm or so)... so now we have to use nitrous b/c our spool time is now a lot longer due to the bigger turbo without the atomization to help get drive pressures up a little to help spool it.
21 pages there, but probably only like 10 were good and technical. the rest was ppl complaining or something. haha. Basically with the little injectors there isn't too much modding they do, but when you start getting larger like 300cc and up then there are internal mods to the fuel and oil sides to allow them to fill and empty faster. such as the 455cc fire hoses w/ 400% nozzles. they empty FAST!!
Since the HEUI injector is unable to create the injection pressure of the common rails or even the VP44 trucks, we have to settle with volume of fuel over atomization to get the HIGH hp numbers from them without blowing them to pieces. now since we don't have that injection pressure/atomization that also means we have to use a larger turbo than should really be neccessary(instead of a 72mm getting us 650hp or so we are using a 76mm or so)... so now we have to use nitrous b/c our spool time is now a lot longer due to the bigger turbo without the atomization to help get drive pressures up a little to help spool it.
Post Fiend
Joined: Oct 2003
Posts: 5,903
Likes: 1
From: MICHIGAN
I couldn't wait to use this haha!
Back on topic below....
Here's a few pictures:
How the PowerStroke injection system works
Swamps FAQ's
Back on topic below....
Here's a few pictures:
How the PowerStroke injection system works
Swamps FAQ's
Hotshot
Joined: Jun 2007
Posts: 10,008
Likes: 7
From: Austin, TX
I couldn't wait to use this haha!
Back on topic below....
Here's a few pictures:
How the PowerStroke injection system works
Swamps FAQ's
Back on topic below....
Here's a few pictures:
How the PowerStroke injection system works
Swamps FAQ's
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