REPAIR GUIDE FOR DENSO COMMON RAIL INJECTOR REPAIR

DISCLAIMER TH E FOLLOW ING DOCUMENT IS BASED ON TH E RESULTS AND EXPERIENCE GAINED FROM STRIPPING, REBUILDING AND TESTING NEW GENUINE DENSO INJECTORS USING H ARTRIDGE ALL MAKES TEST EQ UIPMENT. TH E INFORMATION CONTAINED W ITH IN IS NOT INTENDED FOR USE AS A SUBSTITUTE TO TH E GENUINE DENSO REPAIR PROGRAM.IT@ S CONTENT IS FOR INFORMATION PURPOSES ONLY AND IS TO BE USED AS A GUIDE AND INTRODUCTION TO DENSO COMMON RAIL INJECTOR REPAIR. DIESEL DISTRIBUTORS AUSTRALIA PTY LIMITED AND DIESEL DISTRIBUTORS LIMITED IN NEW ZEALAND ACCEPTS NO RESPONSIBILTY FOR ANY DAMAGE OR INJURY TH AT MAY OCCUR FROM TH E UNAUTH ORISED REPAIR/ADJUSTMENT OF DENSO CR INJECTORS.

Introducti on
Techni caland repai ri nform ati on surroundi ng Denso Com m on Rai li nj ectors outsi de ofthe Denso netw ork i sl i mi ted and scarce,yetthei r use and presence w i thi n the Austral asi an di eselm arketi sw i despread. The f ol l ow i ng docum entai m s to provi de a gui de to usi ng the tool i ng and shi m ki ts together wi th genui ne and non genui ne parts,to stri p,rebui l d and testDenso @ G@@type com m on rai l i nj ectors.The i nform ati on herei n has been gai ned f rom the di sm antl i ng,rebui l d and consequentf l ow and response testi ng ofnew Denso CR i nj ectorsusi ng the H artri dge CriPC and IFT 70 al lm akes program m e.Al terati ons to the shi m adj ustm entofi ndi vi duali nj ectors w ere m ade and the resul ts recorded.These resul ts have been used to determ i ne w hat eff ects any changes to the shi m adj ustm enthave on the overal lperf orm ance ofthe i nj ector. Correcti on codes ( Q R codes)cannotbe w ri tten and produced f or any Denso i nj ector usi ng thi si nform ati on.The producti on and creati on ofQ R codes requi res com pl ex sof tw are and i ntri cate f l ow testi ng usi ng genui ne Denso/H artri dge authori sed equi pm ent.Denso CR i nj ector repai ri nvol ves stri ngentcl ean room practi cesand very ti ghtqual i ty controlon bui l d tol erances.Pl ease take thi si nto consi derati on w hen attem pti ng any di sm antl i ng ofDenso CR i nj ectors. H opeful l y thi s gui de w i l lprovi de an i nsi ghti nto w hatcan be achi eved w i th tool i ng avai l abl e outsi de ofthe Denso of fi ci alrepai r program m e.Consi derati on shoul d be gi ven to the i m portance ofcorrecti on codesw hen undertaki ng any adj ustm entor unoff i ci alrepai r of ANY com m on rai li nj ector thatuses a correcti on code.

Com ponentO vervi ew and Identi fi cati on:

The photo bel ow show s an expl oded stri pped Denso G2 i nj ector and l abel l ed com ponents:

Sol enoi d

Cal i brati on Shi m Sol enoi d Spri ng Shi m Sol enoi d Spri ng Sol enoi d Val ve H al fBal lVal ve Val ve SeatRetai ni ng Nut Val ve Seat NOP Shi m NOP Spri ng Pressure Spi ndl e

Com m and Pi ston Nozzl e

Di sm antl i ng
The f ol l ow i ng di sm antl i ng,rebui l d and testi nstructi ons are based on the use ofthe CR i nj ector ki t( partnum ber @ 850901)and Shi m Ki ts ( 850276,850296,850301)avai l abl e to purchase f rom Di eselDi stri butors,together w i th genui ne and non genui ne repai r parts.

STEP 1 @ Sol enoi d Rem oval

Fi gure 1

Fi gure 2

Fi gure 3

Mountthe i nj ector upri ghti n the vi ce usi ng the correcthol di ng j aw s,dependi ng upon the body type and usi ng the 27m m @ @r@@ @ @@ @@@@gentl yl oosen the sol enoi d( fi g 1) .Once l oose conti nue to l oosen by hand and CAREFULLY and GENTLY rem ove the sol enoi d,taki ng care notto drop the sol enoi d val ve spri ng or tensi oni ng shi m ( Fi g 2) . Rem ove the @ @ @@@cal i brati on @@@ @ @thatw i l lei ther sti l lbe saton the i nj ector or satup i nsi de the sol enoi d body ( Fi g 2) . The sol enoi d val ve can then be rem oved usi ng l ong nose pl i ers.TAKE CARE NOT TO DROP TH E @ @ ALF BALL @AL@E@( Fi g 3) .Thi si s si tuated i n the end ofthe sol enoi d val ve.Iti s sm al l and very easi l yl ost!!@ ( Repl acem entval ves and hal fbal lval ves are avai l abl e through Di esel Di stri butors) .

STEP 2 @ Val ve SeatRem oval

Fi gure 4

Fi gure 5

Fi gure 6

Insertthe Three Pronged Val ve SeatSocketi nto the gui de ( Fi g 4) ,ensuri ng thatthe 3 prongs are l ocated i n the 3 hol es i n the val ve seatretai ni ng screw and then screw the gui de over the socket.Ti ghten the gui de al lthe w ay dow n by hand unti li ti sf el tto @ @@@@@@ @@@@ @then th unscrew by approxi m atel y 1/8 ofa turn ( Fi g 5) .W e need to ensure thatthe i nner 3 pronged socketw i l lturn,w hi l stm ai ntai ni ng m axi m um supportf rom the gui de,m i ni mi si ng the ri sk ofthe socketti l ti ng. W ARN IN G @ Thi s nuti s usual l y very ti ght!.Use a sui tabl e breaker bar and a 14m m socket pl aced over the hex on the 3 pronged socketto undo the val ve seatretai ni ng nut( Fi g 6) .If unsuccessf ul ,use an el ectri c heatgun to appl y GENTLE,MODERATE heatto the nut,then usi ng the brass dri f t,stri ke the nutand re try.DO N O T U SE A BLO W TO RCH !!Excessi ve heat wi l ldam age the i nj ector!

Fi gure 7

Fi gure 8

Fi gure 9

Wi th the val ve seatrem oved ( Fi g 7) ,careful l y rem ove the 2 l ocati ng dow el s( Fi g 8) .Rem ove the i nj ector f rom the hol di ng j i g and turn upw ards,w hi l sthol di ng your hand over the open end ofthe body ( Fi g 9) .The com m and pi ston shoul d sl i de out,or atl eastbegi n to protrude f rom the bore.W i thdraw the pi ston f rom the body.Ifthere i s no m ovem entofthe com m and pi ston atthi s poi nt,i tm ay si gni f y thati ti ssei zed or ti ght.Ifthi si s the case,then i tcan be l efti n si tu to be rem oved af ter the nozzl e end has been di sm antl ed.

STEP 3 @ Cap nutRem oval Rem ountthe i nj ector i n the hol di ng j i gwi th the nozzl e assem bl y poi nti ng upw ards.

Fi gure 10

Fi gure 11

Fi gure 12

As w i th the val ve seatretai ni ng nut,the nozzl e retai ni ng nutcan al so be notori ousl y ti ght. One m ethod thatcan be used to rem ove the nutm ore easi l y and m i ni mi se the ri sk of dam age to the body thread and l ocati ng dow el si nvol vesthe use ofa pi pe cutter to score the cap and @ @ r@@@the thread pri or to rem oval .Iti scom m on practi ce to renew the cap nut on CR i nj ectorsanyw ay,so the cap nutw i l lhave to be di scarded and a new one ( avai l abl e f rom Di eselDi stri butors)w i l lbe f i tted on rebui l d. To rem ove the cap nut,score a l i ne no deeper than 0. 5m m approxi m atel y 15m m f rom the base ofthe nut( opposi te to nozzl e si de)around the cap nut( Fi g 10) .Then,usi ng a good 15m m si ngl e hex socket,undo the nut.There i s a 15m m @r@@ @ @f ootsuppl i ed i n the ki t,but thi si s bestreserved f or ti ghteni ng,i fusi ng an i nj ector al i gni ng j i g. Once the i nj ector cap nuthas been rem oved,the nozzl e can be rem oved al ong w i th the l ocati ng dow el s( Fi g 11) .Fi nal l y,rem ove the i nj ector body f rom the j i g and careful l y turn over,w hi l sthol di ng the needl e spri ng and rem ove the spri ng and spri ng tensi oni ng shi m ( Fi g12). Ifthe com m and pi ston w as notrem oved earl i er due to bei ng ti ghtor sei zed,then i tcan now be gentl y tapped outf rom one end.USUALLY,IF TH E COMMAND PISTON REQ UIRES FORCE TO BE REMOVED,TH E INJECTOR BODY AND PISTON CAN BE CONSIDERED UNSERVICABLE AND NOT W ORTH REPAIRING.

Inspecti on
Sol enoi d assem bl y

Fi gure 13 Resi stance checks shoul d be m ade to the sol enoi d.The speci fi c resi stance m easured w i l l depend upon the type ofi nj ector and shoul d be com pared to a new uni t.The resi stance recorded on the parti cul ar G2 i nj ectors thatw e tested w as approxi m atel y 0. 5 @ 0. 7 Ohm s. Obvi ous si gns ofany dam age to the outer casi ng or spl i ts/cracks on the el ectri calconnector shoul d be observed.Check f or erosi on/corrosi on ofthe el ectri calterm i nal s and ensure that the i nner surf ace ofthe sol enoi di s cl ean and f ree f rom dents etc ( Fi g13). Ensure thatthe sol enoi d spri ng i si n good condi ti on.Itm ay be a good i dea to check and record the l ength agai nsta new one.

Sol enoi d Val ve and H al fBal lVal ve assem bl y

Inspectbal l ,seatand shank

Fi gure 14 Check the condi ti on ofthe sol enoi d val ve assem bl y ,payi ng parti cul ar attenti on to the hal f bal lval ve f ace and the seati nsi de the val ve stem .The f l atf ace ofthe hal fbal lval ve i s responsi bl ef or seal i ng the controlcham ber,so i tm ustbe i n good condi ti on w i th no erosi on or w ear.These com ponents are besti nspected under a m i croscope.Check the coni calseat thatthe bal lseats on i nsi de the val ve,as w el las the val ve stem f or any si gns ofw ear, scratches and erosi on ( Fi g 14) . Renew both com ponents i fthere are any abnorm al i ti esor doubton thei r condi ti on ( both avai l abl ef rom Di eselDi stri butors) .

Val ve Seatand Retai ni ng N ut

Inspectal lsurf acesf or erosi on & w ear

Fi gure 16 Inspectthe val ve seatf or erosi on and w ear ( Fi g 16) .As w i th the bal land val ve assem bl y,thi s i s probabl y bestvi ew ed under a m i croscope or other m agni f i cati on equi pm ent.Ifthere are any m arks across the seati ng area thatw oul d suggesta seal i ng probl em @ renew the val ve seat( avai l abl e through Di eselDi stri butors) . Inspectthe seal i ng f ace ofthe retai ni ng nutf or si gns oferosi on and w ear ( Fi g 16) . Due to the very f i ne tol erances i nvol ved i n CR i nj ectors,l appi ng ofthe seal i ng surf acesof these com ponents i snotrecom m ended.Any attem ptto l ap the surf acesshoul d be undertaken w i th the utm ostcare and w i th the use ofVERY FINE l appi ng pastes.

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Com m and Pi ston & Inj ector Body

Fi gure 17 Check the pi ston f or scori ng and w ear m arks al ong w i th the i nner bore ofthe i nj ector.If there i sconsi dered to be excessi ve scori ng or w ear on ei ther com ponent,then the uni tw i l l m ore than l i kel y be scrapped ( Fi g 17) .The pi ston shoul d be cl ean,f ree f rom scori ng and m ove f reel yi nsi de the i nj ector bore w i th no @ @@@@@@ @@@or ti ghtspots.

N ozzl e Assem bl y,Pressure Spi ndl e and Spri ng. Gui del i nes f or i nspecti ng the nozzl e assem bl y can be consi dered the sam e asf or any conventi onalnozzl e.Check f or excessi ve w ear or scori ng on the needl e shank and seatand renew the nozzl ei fnecessary.( Genui ne and non genui ne nozzl es are avai l abl ef rom Di esel Di stri butors,dependi ng upon appl i cati on and avai l abi l i ty) . Check the spri ng f or condi ti on and the spi ndl ef or excessi ve w ear on the spri ng seat.

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Re Assem bl y
W hen re assem bl i ng any com m on rai lcom ponents,cl ean practi ces shoul d al w ays be observed and the utm ostprecauti on shoul d be taken to avoi d any contam i nati on ofthe com ponents before and duri ng assem bl y. W ARN IN G The torque val ues m enti oned i n the f ol l ow i ng procedure are a SUGGESTED VALUE based upon our experi ence and NOT Denso speci fi cati on.

STEP 1. 2 @ Val ve SeatAssem bl y

Fi gure 18

Fi gure 19

Fi gure 20

Mountthe i nj ector i n the hol di ng j i g and pl ace the 2 l ocati ng dow el si nto thei r bores on the top f ace ofthe i nj ector ( these dow el s are l arger i nl ength and di am eter to the nozzl e l ocati ng dow el s) .Ensure thatthe val ve seati sthe correctw ay round before i nserti ng i ti nto the i nj ector.The bore on the undersi de ofthe val ve needs to be al i gned w i th the bore hol e on the i nj ector f ace ( Fi g 18 & 19) . Usi ng the 3 pronged socket,i nsertand hand ti ghten the retai ni ng nuti nto the i nj ector w i th the seal i ng f ace tow ards the val ve.Screw the gui de over the socket,ensuri ng thatthe socket can sti l lm ove,butw i th m axi m um supportf rom the gui de and ti ghten to 70 75 NM ( Fi g 20) .

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STEP 2. 2 @ Sol enoi d & Sol enoi d Val ve Assem bl y

Fi gure 21

Fi gure 22

Fi tthe hal fbal lval ve i nto the sol enoi d val ve stem and ensure thatthe fl atface ofthe hal f bal lval ve i s vi si bl e and l evelw i th the stem .DO NOT INSERT TH E VALVE STEM INTO TH E VALVE SEAT IF YOU CAN SEE TH E SPH ERICAL PART OF TH E H ALF BALL VALVE ( Fi g 22) .IT MUST BE TH E FLAT SIDE ( Fi g 21) .

Fi gure 23

Fi gure 24

Fi gure 25

The hal fbal lval ve shoul d stay i n the val ve stem w hen turned over and i nserted on the val ve seat.Once the val ve stem i si n posi ti on ensure i ti sf ree by rotati ng i t( Fi g 23) . Pl ace the f uelcal i brati on shi m on top ofthe i nj ector ( Fi g 24) . Next,i nsertthe sol enoi d spri ng shi m and sol enoi d spri ng i nto the sol enoi d and careful l yf i t the sol enoi d onto the i nj ector,ensuri ng thatthe spri ng seats i n the centre ofthe val ve and hand ti ghten.Once hand ti ght,tensi on the sol enoi d assem bl y to 10 12 NM ( Fi g 25) . OVERTIGH TENING OF TH E SOLENOID ASSEMBLY CAN H AVE AN ADVERSE AFFECT ON TH E OPERATION OF TH E INJECTOR AND MAY RESULT IN DAMAGE TO TH E SOLENOID.

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STEP 3. 2 @ N ozzl e and Cap N utAssem bl y

Fi gure 26

Fi gure 27

Fi gure 28

Re posi ti on the i nj ector assem bl yi n the j i gwi th the sol enoi d tow ards the bottom . Insertthe com m and pi ston i nto the i nj ector body w i th the m ai n shank m achi ned w i th grooves tow ards the sol enoi d end ( Fi g 26) . Nexti nsertthe nozzl e openi ng pressure shi m and the spri ng i nto the centrali nj ector bore and then i nsertthe pressure spi ndl e on top ofthe spri ng w i th the sm al l er di am eter f aci ng the nozzl e needl e( Fi g 27. ) Insertthe l ocati ng dow el si nto the seal i ng f ace and pl ace the i nj ector over them .Pl ace the ( new )cap nutover the nozzl e and screw dow n unti lhand ti ght( Fi g 28) . Ideal l y som e ki nd ofi nj ector cl am pi ng ri g shoul d be used to unsure al i gnm entofthe nozzl e, i fyou can f i nd som ethi ng or m anuf acture anythi ng sui tabl e to hol d the body.The arrangem entpi ctured bel ow ( Fi g 29)f eatures the Stanadyne Inj ector Al i gni ng Tool( Part# 29617) .An i nj ector al i gni ng toolw as notused i n thi s exerci se and no operati onalprobl em s w ere experi enced,how ever i tw oul d be better to use one i favai l abl e to m i ni mi se the ri sk of mi sal i gnm entor breaki ng the dow elpi ns.

Fi gure 29

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Testi ng
Al ltesti ng ofthe Denso CR i nj ectors used to obtai n the i nform ati on gi ven here w as com pl eted usi ng the H arti dge CRI PC and the IFT 70.( both avai l abl ef rom Di esel Di stri butors) W hen testi ng Denso Com m on Rai li nj ectors the f ol l ow i ng el em ents shoul d be observed to eval uate and determ i ne the f uncti onal i ty and condi ti on ofthe i nj ector: 1 Nozzl e openi ng pressure 2 Inj ector Response Ti me 3 FuelDel i very 4 Back l eakage 5 Back l eakage tem perature Each ofthe above w i l lbe di scussed i n m ore detai li n the f ol l ow i ng gui de w hi ch hopes to provi de an understandi ng ofw hatef f ectal teri ng the shi m adj ustm enthas on the @ @@ @@@@r@ @ perf orm ance.

1. N ozzl e N eedl e openi ng pressure Thi s can be setby the shi m thatsi ts behi nd the nozzl e spri ng.The nozzl e openi ng pressure setti ng on a G2 i nj ector w i l lhave an eff ecton f ueldel i very and Response Ti m e (see further dow n i n secti on 2 for defi ni ti on)parti cul arl y atl ow er engi ne speeds and rai lpressures.Ifthe openi ng pressure i s settoo l ow ,the i dl e del i very and pre i nj ecti on w i l li ncrease.Ifthe openi ng pressure i s settoo hi gh the i dl e and pre i nj ecti on w i l ldecrease and response ti mewi l li ncrease.Fuel l i ng and response ti m e at m ai nf uel l i ng setti ngs w i l lrem ai nl argel y unaf fected. W e can setthe openi ng pressure w i th the use ofa H artri dge IFT 70 i nj ector f uncti on tester thatcan actuate the sol enoi d w hi l stthe user can observe the spray pattern and controlthe rai lor f eed pressure.Thi s exerci se coul d possi bl y be perf orm ed w i th a conventi onali nj ector tester and a m ul ti f uncti on CR i nj ector tri gger box such as the IFT C ( avai l abl ef rom Di eselDi stri butors) . TH IS TEST SH OULD BE CARRIED OUT AND SET ( IF NECESSARY)BEFORE ANY FLOW TESTING OF TH E INJECTOR.

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Mountthe i nj ector i nto the m achi ne and connectthe hi gh pressure pi pe and appropri ate el ectri calconnector.

Fi gure 30

Fi gure 31

Usi ng a l arge pul se w i dth ofaround 2. 5 m /s and l ow i nj ecti on speed ofsay 100 i nj ecti ons per m i nute ( IPM)( Fi g 30) .Setthe f eed ( rai lpressure)to zero and gradual l yi ncrease unti lthe f uelcan be seen to i nj ect.Atthi s poi nttake note ofthe pressure on the gauge atw hi ch i nj ecti on started to take pl ace. ( Fi g 31) . The openi ng pressure on the parti cul ar Denso i nj ector tested w as approxi m atel y 130 140 bar.Thi sf i gure m ay di ff er dependi ng upon i nj ector partnum ber.Itw i l lbe up to the user to gai n som e speci f i cati ons f rom new i nj ectors. Ifthe pressure needs to be adj usted,then the openi ng pressure shi m wi l l need to be changed to i ncrease or decrease spri ng tensi on accordi ngl y.Si nce the nozzl e cap nutw i l lnothave been puti nto servi ce the l ooseni ng and re tensi oni ng shoul d notcause any i ssuesand shoul d be abl e to be re used af ter rem oval . A check ofthe spray pattern and generaloperati on ofthe i nj ector can then be perf orm ed w hi l ststi l lm ounted on the IFT 70 af ter the openi ng pressure has been checked.As a generalrul e @ there shoul d be no m ore than 30 40% back l eakage del i very com pared w i th f ueldel i very on f ul ll oad setti ngs( e. g. 500bar @ 1200PPM @ 1. 2 m /s pul se w i dth w hen usi ng the IFT 70) . Ifthe i nj ector i sf uncti oni ng properl ywi th basi c del i very,back l eakage and spray pattern al lsati sf actory,the i nj ector can be f l ow ed m ore accuratel ywi th the H artri dge CRI PC or AVM2 w i th CR i nj ector al lm akes capabl e ofchecki ng f ueldel i very,back l eakage and response ti m e athi gh pressures ( 1600 bar +) .

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2. Response Ti me Si m pl y expl ai ned @ thi si s the ti m e taken f rom w hen the ECU sends a si gnal( current)to the i nj ector to w hen the actuali nj ecti on takes pl ace. Iti san i m portantf actor i n determ i ni ng the condi ti on ofthe i nj ector.In general i ncreased response ti m e poi nts tow ards a poorl yf uncti oni ng i nj ector.On vehi cl e eff ects ofpoor response ti m e can show as w hi te sm oke,rough runni ng,i dl i ng probl em s, detonati on ( knocki ng)and poor perf orm ance. Inj ector response ti mei s an i m portantf actor f or the ECU to be abl e to @ @@@ @@@@@@@@ dri ve pul se f or recal cul ati ng f uelquanti ti es f or on vehi cl e@ @ @@r@@ @@@ofQ R codes. Response ti m e can be af f ected by openi ng pressure,com m and pi ston condi ti on,nozzl e condi ti on,sol enoi d val ve condi ti on and sol enoi d eff i ci ency.Anythi ng thatcan eff ecti vel y @ @@ @@ d@@ @@the operati on ofthe i nj ector w i l lresul ti ni ncreased response ti m e. Ifresponse ti m e can be read and seen then a cl earer pi cture can be gai ned f rom the i nj ector teston the generalcondi ti on ofthe i nj ector,as opposed to onl y rel yi ng upon m easuri ng del i very and back l eakage.Itcan be consi dered i m portanti n our di agnosi s of i nj ector condi ti on.Itcan be af f ected by changi ng f uel l i ng shi m s and openi ng pressure. Typi calresponse ti m es recorded f or the Denso i nj ectors tested w ere i n the regi on of 430 490 @@for hi gher pul se w i dth and pressure setti ngs ( ful land m i dl oad scenari o) . Response ti mewi l lgeneral l yi ncrease ati dl e and l ow er pul se w i dthsand pressures ( i dl e, partl oad and pre i nj ecti on) .Typi cali dl e response ti m es m ay be around 490 560 @@@ Agai n,the above f i gures are based upon the testi ng ofcertai n Denso i nj ectors and to gai n a m ore thorough understandi ng ofi nj ector speci fi c response ti mef i gures,new i nj ectors w oul d need to be tested and resul ts recorded.

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3. FuelDel i very After the openi ng pressure has been setand the i nj ector hasbeen tested f or basi c f uncti on i tcan then be properl yf l ow ed f or a m ore i n depth teston the H artri dge AVM2 PC w i th i nj ector al lm akes ki tor the H artri dge CRI PC. The i nj ector needs to be gi ven a @ @@@@@@ @@@ofsetti ngs f rom w hi ch the resul ts can be recorded.These varyi ng setti ngs shoul d putthe i nj ector through di ff eri ng testsi tuati ons thatw oul d bestsi m ul ate vari ous engi ne condi ti ons.An exam pl e ofthese testcondi ti ons has been i ncl uded bel ow f or ref erence: ( Fi g 32) .
TOYOTA 23670 0L090 BEFORE ADJUSTMENT Inj ector # Pul se Pressure ( bar) Speed w i dth @ @@@ Idl e 400 350 750 Mi d Range 1000 800 800 Ful lLoad 1600 1500 1000 Stati c Leak 1600 1000 0 Pre Inj ecti on 600 1000 500 Mi d Range 800 1200 800 Start 950 150 1000 Del i very Back Leak ml /st ml /st 12. 4 14. 9 49. 3 22. 8 95. 2 33. 8 0 0 9 14. 7 39. 9 19. 6 64. 2 105. 6 Response @ @@@ Return Tem p @C 489 39 432 40 418 50 0 52 452 49 446 51 551 48

Fi gure 31 @ TestPl an Exam pl e Once a setoftests or @ @@@d@ @@ @@@@have been deci ded upon,they can then be used asa generi c testpl an f or al m ostal li nj ectors.The testpl an i sthen used to record the resul ts f rom new i nj ectors and used f or com pari son agai nstused or @ r@@@@ r@d@uni ts.A database ofresul ts can be bui l tup and tol erances can even be f orm ed by testi ng m ul ti pl e new uni ts and taki ng average readi ngs,f rom w hi ch tol erance bands can be deci ded. Ifthe f l ow resul ts f rom a used or repai red i nj ector are deem ed to be @ @@@of@@@@@w hen com pared to a testresul tf rom a new i nj ector then the f ueldel i very can be al tered by changi ng the Cal i brati on Shi m w hi ch si ts i n betw een the sol enoi d and the i nj ector body. CH ANGING TH IS SH IM W ILL H AVE AN EFFECT ON TH E OVERALL FUEL DELIVERY OF TH E INJECTOR. To INCREASE the f uel l i ng a TH ICKER shi m m ustbe f i tted To DECREASE the f uel l i ng a SMALLER shi m m ustbe f i tted.

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0. 1 m m di f f erence i n shi m si ze w i l lequate to an approxi m ate 7% change i nf uel l i ng across the w hol e range ofthe i nj ector.H ow ever,the response ti m ewi l lal so change as w e have eff ecti vel y changed the totaldi stance thatthe sol enoi d val ve has to travel .In an eff ortto counteractthe resul ti ng response ti m e change,the sol enoi d spri ng shi m can be changed to try and l i mi tthe resul ti ng di ff erence i n response ti m e.Al though a di f f erence i n response ti mei s seen w hen the sol enoi d spri ng shi m i s changed,i ti s mi ni m aland doesnotreturn to the ori gi nalresul tsaf ter a m ai n cal i brati on shi m al terati on. Itw oul d theref ore be prudentto m ake onl y sm al lal terati onsto the cal i brati on setti ng w hen consi deri ng any changes to the f uel l i ng ofthe i nj ector. Changi ng the sol enoi d spri ng shi m wi l lal so af f ectf ueldel i very asw el las response ti m e, asw e are reduci ng or i ncreasi ng spri ng tensi on on the sol enoi d val ve,m aki ng i teasi er or harder f or the sol enoi d to pul lup the val ve.Agai n,consi der the eff ects to the f uel l i ng throughoutthe range w hen attem pti ng any shi m adj ustm ent.

4 Back l eakage & Back l eak Tem perature The am ountofback l eakage f uelthata CR i nj ector produces i san i ndi cator ofthe i nternalseal i ng and condi ti on ofthe i nj ector.Any probl em sw i th the seal i ng ofthe sol enoi d val ve or the nozzl e needl ewi l lshow up as hi gh back l eakage.Usual l y,i fhi gh back l eakage i s experi enced i tw i l lbe seen i n every testand can i ndi cate val ve seat probl em s,sol enoi d val ve probl em sand nozzl e seal i ng or w ear i ssues. Back l eakage tem perature i s al so w orth m oni tori ng,asany excessi ve l eakage ofhi gh pressure f uelw i thi n the i nj ector w i l lcause the tem perature ofthe back l eakage to ri se. Thi si s because the hi gh pressure f uelcreated i n the rai li sa l othi gher tem perature than the l ow er pressure ofthe back l eakage,theref ore any excessi ve ri se i n back l eaked f uel wi l lshow up asa hi gh back l eak tem perature.

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Correcti on Codi ng & Batchi ng

CR i nj ector correcti on codi ng i si m portantand al l ow s the CR system asa w hol e to com pensate f or m echani caland hydraul i c tol erances w i thi n the i nj ector.No tw o i nj ectors w i l lnatural l yf l ow the sam e and the vehi cl e ECU can com pensate f or thi s by al teri ng the pul se w i dth to i ndi vi duali nj ectors w hen the correcti on code gi ven to the i nj ector duri ng m anuf acture i s program m ed i nto the ECU. W e cannotproduce thi s code w i th conventi onalal lm akes equi pm ent.Itrequi res a consi derabl ei nvestm entand OEM backi ng to do so. One m ethod oftryi ng to l i mi tthe probl em ofour i nabi l i ty to produce an i ndi vi dual correcti on code i sto @ @@@@@@i nj ectors.Thi s m ethod i nvol ves f l ow testi ng and adj usti ng the f ueldel i very on i nj ectors so thatthe di f f erencesbetw een them are m i ni m al .Say f or i nstance w e had around 30 i nj ectors thatw ere @ r@@@@ r@d@and f l ow tested.The batchi ng concept assum es thatoutofthose 30 i nj ectors there w oul d be @ @@@@@thatw oul d di spl ay si mi l ar f l ow and response characteri sti cs.These i nj ectors coul d then be f urther @ @ @ @@ @@@@d@w i th m i nor adj ustm entto m ake them as si mi l ar to each other aspossi bl e. Sets of4 or 6 i nj ectors are then sol d or f i tted together to m i ni mi se any m aj or di f f erences i nf l ow . Another concepti s to bui l dl engthy data base on the f l ow rates ofdi ff eri ng new i nj ectors f rom sam e partnum ber f am i l y by recordi ng thei rf l ow and response characteri sti csand the code on thatparti cul ar i nj ector.Over ti m e a database can be bui l tand any f uture i nj ectors thatdi spl ayed si mi l ar resul ts to a previ ousl y recorded uni tw oul d be gi ven the code f rom thatsi mi l ar f l ow i ng new i nj ector.Thi s w oul d be a l ong and com pl i cated process,butnoti m possi bl e.

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SU MMARY There are parts,testequi pm entand tool i ng avai l abl e through Di eselDi stri butors to servi ce and testDenso CR i nj ectors.There i s no concrete setofi nstructi ons or testdata to produce a perf ectl y repai red product.There i s how ever,an openi ng to be abl e to of f er som ethi ng m ore than j usta new uni ti n box. The repai r conceptof fered here i s to enabl e the user the abi l i ty to @ @ @@r@ as you @@@and base repai rs on data obtai ned f rom new uni ts. H opeful l y,the i nform ati on i n thi s docum enti s enough to getyou started. For further i nform ati on pl ease contact: Di eselDi stri butors Austral i a @ Peter H unter peterh@ ddal . com . au Di eselDi stri butors N ew Zeal and @ Kevi n Morri s kevi n@ di esel d. co. nz

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