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CRM-100 Common Rail Rail Injector Injector Repair Tool Tool Sets Instruction Manual
DENSO G2 Injectors
INJECTRONI CO., LTD. 1
CRM-100 Common Rail Injector Measurement System
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1. Injector body 2. Valve plunger 3. Dowel 4. Calibration shim, B23, ID3.15mm, OD 5.75mm, thickness 1.0-2.5mm 5. Spring 6. spacer 7. Nozzle 8. Nozzle nut 9. O-ring 10. Copper washer 11. Plastic cap 12. Solenoid 13. Calibration shim, B24, ID 1.7mm, OD 3.95mm, thickness 1.0-1.5mm 14. Spring 15. Armature 16. Ball 17. Nut 18. Valve spacer 19. Dowel 20. O-ring 21. Calibration shim, B27, ID 21.5mm, OD 24.3mm, thickness 1.5-1.72mm
To measure total 3 calibration shims
2
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – on Nozzle Side Task 1 – Adjust Needle Opening Pressure (1)
Clamp injector on a vise with injector clamping tool. Loose nozzle nut (8)
Remove calibration shim B23 (4)
Install micrometer with extension rode 511012 on frame 970100. Place platform 511020 on frame 970100. Adjusting micrometer height by the hand wheel, then lock
the
moving
beam
by
the
handles.
Zero
micrometer on platform 511020. Caution: Pay close attention when adjusting micrometer mounting arm downward, to prevent micrometer damage.
3
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – on Nozzle Side Task 1 – Adjust Needle Opening Pressure (2)
Measure the thickness of shim B23
Fasten injector by using the matching holder on frame 970100.
Place shim B23 (4) and spring (5) in injector cavity.
4
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – on Nozzle Side Task 1 – Adjust Needle Opening Pressure (3)
Place 1mm thickness gauge on the injector. Adjusting
the
position
of
micrometer.
Zero
micrometer on the thickness gauge.
Remove the thickness gauge. Place spacer (6) in injector
Place 1mm thickness gauge on it.
Measure the top
of thickness gauge.
5
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – on Nozzle Side Task 1 – Adjust Needle Opening Pressure (4)
If the measured value does not meet requirement, replace calibration shim B23 with thickness indicated on PC screen
Fasten nozzle nut with torque 90Nm
6
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 2 – Inspect Weariness of Valve Spacer (1)
Loose solenoid (12) from injector.
Remove calibration shim B27 (21), calibration shim B24 (13), spring (14),
armature (15), and ball(16)
Loose nut (17) by using special tool.
7
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 2 – Inspect Weariness of Valve Spacer (2)
Remove valve spacer (18). Check the sealing surface by using the microscope
The spacer with light weariness is still usable. Replace the severe worn one with new part.
8
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 2 – Inspect Weariness of Valve Spacer (3)
Place The ball (16), with flat surface up, on the cavity at the end cavity of armature (15 ).
It is wrong to place the ball with spherical surface up.
9
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 3 – Adjust Armature Lift (1)
Zero micrometer on platform 511020
Measure the thickness of shim B27
Fasten sleeve
970539 and extension probe 511011
on micrometer
10
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 3 – Adjust Armature Lift (2)
Zero micrometer on platform 511020
Measure solenoid. Note: DO NOT place shim B27 in the cavity of solenoid
Zero micrometer on platform 511020
11
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 3 – Adjust Armature Lift (3)
Place shim B27 in the cavity of injector. Measure injector
If the measured value does not meet requirement, replace calibration shim B27 with thickness indicated on PC screen. Tighten solenoid with torque 12-15Nm.
12
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 4 – Adjust Solenoid Spring Compression (1)
Fasten micrometer and platform 511020 on frame 970100. Zero micrometer on platform
Measure thickness of shim B24 (13)
Fasten sleeve 970539 and extension rod 511011 on micrometer.
13
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 4 – Adjust solenoid spring Compression (2)
Place shim B27 in to cavity of solenoid.
Hold micrometer with sleeve 970539 firmly against solenoid. Zero micrometer.
Place spring (14) and shim B27(13) in solenoid cavity.
14
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 4 – Adjust solenoid spring Compression (2)
Measure solenoid. If the measured value does not meet requirement, replace calibration shim B24 with thickness indicated on PC screen
15
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 5 – Adjust Armature Lift by Electronic Driving Signal (1)
Loose the screw on the top center of solenoid.
Fasten injector by a matching holder on frame 970100. Connect injector terminal and C-Box with cable.
Click the button on PC screen to trig electronic driving signal. The measurement of armature lift w ill be done automatically by the system.
16
CRM-100 Common Rail Injector Measurement System
http://www.injectronix.com
Working Procedure – Solenoid Side Task 5 – Adjust Armature Lift by Electronic Driving Signal (2)
If measured value does not meet required armature lift, loose solenoid from injector body. Replace shim B27 by system recommendation.
17
CRM-100 Common Rail Injector Measurement System