Newsroom

Visit the Newsroom and browse the latest news articles and press releases to find out more about Delphi Technologies.

About Us

With a presence in more than 150 countries, and a global network of over 2750 service centres, Delphi Technologies aftermarket provides OE specification end-to-end solutions from components to sophisticated software solutions.

Sabre CRi Master
Resource Centre 5 min read

Coding 101 | Sabre Series

Share Resource:
Diagnostics & Test Equipment Hartridge Sabre CRi Expert Technical Tip Technicians 5 min read

Resource Highlights

 We seek to do this to the highest criteria with the correct methods, even if these methods mean we can’t take a quick & easy path to providing workshops with what they need to achieve these OEM standards. 

For us CR injector coding, if it is to be done correctly, is simply a means of ensuring that an injector which passes the Hartridge test plan is then calibrated to perform as originally specified by the OEM. 

Coding, Correction Code, Grading or Trims?  

These are all common terminology used for generating a new code for a reconditioned injector.  In essence coding, correction code and grading all refer to the same thing - an alphanumeric code which is assigned to an injector. 

The alphanumeric code varies in length between different Fuel Injector (FI) manufacturers and different product families. The term trims however is the odd one out. 

It’s possible that OE test methods may have over 400 measurement points to determine the performance characteristics of an injector, although from the 400 points there are really only a handful of critical measurements points, i.e. 16, which are used for generating a new code and these are known as trims. This refers to the performance offset or error at a critical measurement point against where the injector should be performing. 

Workshop’s relationship with coding 

Some workshops question the importance or relevance for coding on high, 100k mileage vehicle due to engine wear and tear. Many simply believe that that the ECU can automatically adjust the injector performance using closed loop control to bring the injector back to OEM standards during a “re-learn” period. 

While this is technically true, this nonetheless misses the fundamental point of the need to validate if an injector is functioning back to OEM standards once refitted, or if it requires further adjustment. 

Some workshops listen for engine “knock” at idle and fast idle, some will check the exhaust for coloured smoke, and others take the vehicle for a test drive to check for smoothness and power delivery. 

Some will even use a diagnostic tool to check the level of fuel compensation at idle, (normally shown in % fuel trim).  These methods provide a good indication of the presence of injector faults and incorrect coding. 

However, because they are based on trial & error as well as being reliant on the experience of the mechanic, they are ultimately not a measurable way of proving a quality repair has been conducted, nor is this a wise use of a mechanic’s valuable time. 

What does coding really add to what a workshop can do? 

None of these methods do anything to confirm if the injector is performing back to OEM standards across the complete engine operating range, and more importantly, do not confirm complete and optimised combustion to ensure NOx and particulate matter is minimised to comply with the applicable emissions standard for that particular injector. 

So is CR injector coding just a marketing gimmick to tell workshops they need to invest in another piece of equipment?  

The answer from any serious player in the diesel industry is a resounding “No”. Coding is fundamentally the most important aspect of CR injector calibration because new and reconditioned injectors alike need to be re-aligned to deliver the correct quantity of fuel at the right time during the combustion stroke, to meet stringent emissions standards. 

However, the coding itself is only as good as the quality and accuracy of the test to be able to assign the correct code in the first place. This is the second part of the story. 

The effort to develop an All-Makes OEM quality coding solution requires a considerable amount of R&D activity. This is because each FI manufacturer uses different measurement strategies to determine the injector code definition and trim.  

For Hartridge, the only sure way to determine each strategy is to perform a substantial amount of reverse engineering, utilising our extremely diligent R&D processes gained from our OE heritage and knowledge. 

We recognise that any deviation from this process allows variables to be unaccounted for; a cardinal sin in the Hartridge engineering team! 

However, most importantly it is imperative to perform on vehicle testing and use a process involving comprehensive data collection to reverse engineer the injector behaviours and fully understand the on-vehicle ECU drive logic and trim corrections.  

What ‘proper’ coding looks like 

One of the most unique injector manufacturer strategies is for Bosch Piezo injectors.  Bosch performs a test known as “ISA”, which stands for Injector Learn Voltage. This test determines the required injector voltage to energise the piezo stack and deliver a pre-defined quantity of fuel.  

This learned voltage is then translated into a single letter and is utilised as the last character within the final code. However that learned voltage is more than just a letter identifier, it also defines a voltage correction parameter for all the other test steps in the injector test.  

Failure to apply this voltage correction parameter in the right way, or at all, will result in offset fuelling values and therefore incorrect codes being generated. This in turn has the potential to create incomplete combustion, high levels of NOx and particulate matter, even though the engine may seem to operate correctly! 

Another great example is Denso G2/G3 coil injectors where it is absolutely mandatory to utilise forced air to cool the injector body during testing. Hartridge wanted to avoid using forced air cooling on the Sabre CRi to prevent additional service connections being needed for the machine. 

However extensive R&D testing identified that it was impossible to achieve a consistent and repeatable result due to internal component separation due to overheating. The HJ088 air cooling kit, developed specifically for the Sabre CRi Master and Sabre CRi Expert, provides a significant advantage when coding Denso G2/G3 coil injectors as demonstrated in the graph. 

Unfortunately, no other advanced injector control strategies could eliminate the requirement for forced air cooling, as the electrical coil energy is not affected by heat. Therefore this has resulted in forced air cooling across the injector body being the only viable option to provide a grading solution which mirrors OEM standards. When we say that we will take the correct path even if it isn’t the easy path this is what we mean. 

However, not only is forced air cooling a requirement for Denso coding but also a closed loop test strategy is required with a varying number of test points depending on the application being tested to generate the required trim parameters.  This can vary between 6 and 11 steps depending on the injector and how the Hartridge test plan has to be designed to enable on vehicle conditions. 

One thing Hartridge can confirm is that if your test solution is not performing dedicated test steps and different measurement strategies for each FI manufacturer then you can be assured that your coding solution is not testing the injector to OEM quality standards and it could just be a marketing gimmick. 

In a world where emissions standards are continuing to tighten and compliance testing becoming more prevalent, it will be the responsibility of the diesel industry as a whole to ensure it achieves best practice in the testing, repair and calibration of injectors. 

The specified form no longer exists or is currently unpublished.

Related article resources and products

    Part diagnostics fuel injection electronic test kit
    Diagnostics & Test Equipment Fuel Injection Diagnostic

    Electronic Injector Test Kit

    With today’s Common Rail injector technology, it’s no longer sufficient to just measure resistance to check a coil’s health – you also need to measure inductance for an immediate and accurate assessment. Previously separate tools would have been needed for this. Not with our Electronic Injector Test kit. Otherwise known as the ‘buzz tool,’ or part number YDT720, you’ll be able to quickly test the electrical integrity of all makes of solenoid Common Rail injectors on vehicle. The simple,hand-held tool measures the injectors core criteria, allowing you to quickly compare values and identify if any are not within a comparable performance range, or confirm specific electronic failures which may indicate an unrepairable injector. You can also use it in conjunction with our solvent cleaning kit to resolve early-stage lacquering. All with just one tool, saving significant time and cost for the garage.
    pt-dte-pass-banner
    Diagnostics & Test Equipment

    Pass-Thru Diagnostics

    Our DS-Flash™ pass-thru package does what its name suggests – it allows garages to ‘pass-thru’ to vehicle manufacturer’s websites to access valuable repair and maintenance information. With DS-Flash you’ll be able to perform dealer-level diagnostics, download software updates, reprogram ECUs and access OE technical data and service schedule information, without the need for expensive dealer-only tools. The full kit is compliant with VM programming requirements and comes complete with a DS-Flash™ VCI, cables, a battery support unit and a laptop PC, pre-configured for key brands. Users will also benefit from our 12-month support package, which includes training and technical support for both the equipment, registration to the VM web portal and installation and use of the VM software. So from now on, jobs that were turned away, or referred back to the dealer network, can now be managed in house.
    Part diagnostics fuel injection hd3000 high pressure tool
    Diagnostics & Test Equipment Fuel Injection Diagnostic

    HD3000 High Pressure Diagnostic Tool

    Designed for specialist workshops, our patented HD3000, part number YDT840, simplifies the diagnosis of faults with current and future-generation diesel and gasoline high pressure fuel systems, on all vehicle types. With one tool users will be able to safely set and electronically control any pressure testpoint , up to 3000 bar, in order to investigate the full range of pressures and analyse the performance of the fuel injection system – previously this level of flexibility, accuracy and pressure capability could only be achieved with a system-dedicated test bench. Containing an electronic control device, hydraulic block and electrical device, it incorporates multiple dedicated test routines, as well as an IMV cleaning procedure. All this can be achieved without changing any ECU parameter, dismantling the fuel injection system, or taking the vehicle out on a road test – helping workshops save valuable time and deliver faster service turnarounds.
    Part diagnostics fuel injection lo35 low pressure tool
    Diagnostics & Test Equipment Fuel Injection Diagnostic

    LP35 Low Pressure Diagnostic Tool

    Designed for the garage technician, LP35, part number YDT810, is a highly precise, ultra-fast, affordable hand-held tester for the low-pressure side of light, medium and heavy duty vehicles. With a single tool, you can perform quick and accurate pressure analysis across a wide range of positive and negative pressures, from minus one through to positive 35 bar -that’s why we called it the LP35. Unlike other entry level equivalents, it’s also compatible with most low-pressure circuits, as well as different fluids, so you’ll no longer need separate negative and positive pressure tools, saving both time and money. Add to this its static and dynamic functionality, and you’ve got a highly versatile, highly capable low-pressure tool.
    Part diagnostics fuel injection hd3000 high pressure tool blueprint
    Diagnostics & Test Equipment

    Fuel Injection Diagnostics

    Due to the design of today’s advanced fuel injection technology, electronic diagnostic tools require additional support to accurately trace faulty components – the ECU diagnostic software  can often go no further than failure mode identification, which does not always pinpoint the particular part of the system that has failed and can result in the unnecessary replacement of complete systems. That’s where we come in. We know exactly what is required when diagnosing this technology – after all, the chances are we designed and manufactured it in the first place. So, we’ve developed a range of simple, low-cost, on-vehicle diesel diagnostic tools to help you and your customer save time and money.
    Part diagnostics fuel injection sealed rail kit
    Diagnostics & Test Equipment Fuel Injection Diagnostic

    Sealed Rail Diagnostic Kit

    Because Common Rail systems operate at extremely high pressures, any loss in pressure will have a knock-on effect on the vehicle – causing a progressive reduction in power and even a complete engine shut down. It is therefore imperative that any such issues are identified and resolved as early as possible. We have just the answer. Our Sealed Rail diagnostic kit, part number YDT850, provides simple, low-cost on-vehicle capability for all makes of Common Rail pumps and injectors. Consisting of a sealed rail pressure tester and injector back leakage measurement equipment, users can check the pressure being generated by a Common Rail pump and identify individual injectors that fail, meaning only faulty components will need to be replaced.
      where to buy

      Find out where to buy Delphi Technologies parts

      where to repair

      Find your nearest Service & Diesel Centres