DENSO X2 Instruction

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CRM-100 Common Rail Rail Injector Injector Repair Tool Tool Sets Instruction Manual

DENSO X2 Injectors

INJECTRONI CO., LTD. 1

CRM-100 Common Rail Injector Measurement System


1. Solenoid 2. Calibration shim, B** ID20mm, OD23.2mm, Thickness 2.98-3.10mm ，

3. Armature 4. Ball 5. Nut 6. Valve spacer 7. Spacer 8. Dowel 9. Valve plunger 10. O-ring 11. Injector body 12. Spacer 13. Calibration shim, B23, ID 3.15mm, OD 5.75mm, thickness 1.0-2.5mm 14. Spring 15. Pin 16. Dowel 17. Spacer 18. Dowel 19. Nozzle 20. Nozzle nut 21. Plastic cap

To measure total 2 calibration shims

2



Working Procedure – on Nozzle Side Task 1 – Adjust Needle Opening Pressure (1)

Fasten injector on a vise with injector clamping tool. Loose nozzle nut (20)

Remove Calibration shim B23 (13), spring (14), spacer (12).

Install micrometer with extension probe 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




Measure the thickness of shim B23 (13). (13) .

Fasten injector by using the matching holder on frame 970100.

Place spacer(12) and shim B23 (13) in injector cavity.

4




7. Place 10mm thickness gauge on the injector. injector. Adjusting the position of micrometer.

Zero

micrometer on the thickness gauge.

8. Remove the thickness gauge. Place spring(14) and spacer (15) in injector

9. Place 10mm thickness gauge on it.

Measure the top

of thickness gauge.

5




10. If the measured value does not meet requirement, replace calibration shim B23 with thickness indicated on PC screen

11. Fasten nozzle nut with torque 90Nm

6



Working Procedure – Procedure – Solenoid Side Task 2 – Inspect Weariness of Valve Spacer (1)

Loose solenoid (1) from injector.

Remove calibration shim B44 2), armature(3), and ball(4)

Loose nut (5) by using special tool.

7




Remove valve spacer (6). Check the sealing surface in the center by using the microscope

The valve spacer with light weariness is still usable. Replace the severe worn one with new part.

8




Place The ball (4), with flat surface up, on the cavity at the end cavity of armature (3 ).

It is wrong to place the ball with spherical surface up.

9



Working Procedure – Procedure – Solenoid Side Task 3 – Adjust Armature Lift (1)

Zero micrometer on platform 511020

Measure the thickness of shim B44

Install injector on the frame 970100 by using respective holder.

10




Extension rod 511011 and sleeve 97039 on micrometer.

Place calibration shim B44 (2) on injector

Place 1mm thickness gauge 511015 on shim B44

11




Zero micrometer on the thickness gauge

Remove the thickness gauge and then measure injector

If the measured value does not meet requirement, replace calibration shim B44 with thickness indicated on PC screen..

12




Using the shim B44 of correct thickness to assemble the injector. Fasten solenoid, torque 12-15Nm

13


DENSO X2 Instruction

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