Recommended Tools KO1521 – Denso Repair Tool Tool Set
a)
KO1519 – Denso Solenoid Air Gap Measuring Tool.
b)
KO1559 – Denso Nozzle Holder Removing Tool Set
c)
KO1379 – Nozzle Lift Measuring Set for Maltese Cross end CR Injectors.
d)
BA1426 - Denso Fixing Nut Removing Tool
Recommended Tools KO1475 Clean Bench
Recommended Tools KO1560 Digital Torque Wrench
Recommended Tools Additional Items
Lapping Plate and necessary paste or fine sand paper
Dial Gauge, preferably Digital 0-10 mm with 0.01 mm sensitivity.
Torx Screw Driver – 3 mm for Magnet Plate Screw.
Description of Components Passenger Car and Light Commercial Vehicles
1
Solenoid
9
Injector Body
2
Solenoid O-ring
10
Command Piston
3
Solenoid Spring Adjustment Shim
11
Nozzle Spring Adjustment Shim
4
Solenoid Spring
12
Nozzle Spring
5
Air Gap Adjustment Washer
13
Centering Piece
6
Spindle
14
Pins
7
Fixing Nut
15
Nozzle
8
Orifice Plate
16
Nozzle Holder
Description of Components Trucks and Heavy Duty Applications
1
Solenoid
10
Command Piston
2
Solenoid O-ring
11
Shim Support
3
Solenoid Spring Adjustment Shim
12
Nozzle Spring Adjustment Shim
4
Solenoid Spring
13
Nozzle Spring
5
Air Gap Adjustment Washer
14
Needle Pin
6
Spindle
15
Spacer
7
Fixing Nut
16
Spacer Pins
8
Orifice Plate
17
Nozzle
Disassembling the Solenoid and the Control Valve Mechanism WARNING! Clean the complete injector in the ultrasonic cleaning tank before disassembling the injector.
Release the Solenoid
Disassembling the Solenoid and the Control Valve Mechanism
Carefully remove spring shim and spring. Make sure to take the air gap adjustment washer out. (Some models do not have shim, check carefully!)
Disassembling the Solenoid and the Control Valve Mechanism
Remove the o-ring on the injector.
Disassembling the Solenoid and the Control Valve Mechanism
Use the tweezers to take the spindle out.
Disassembling the Solenoid and the Control Valve Mechanism
Spray some rust remover into the holes of the fixing nut. Wait for 5-10 min for the rust remover to be effective on the threads.
Mount the injector on the injector clamp and place the BA1426 Denso Fixing Nut Removing Tool. Clamp the tool onto the surface of the fixing nut as shown in the
Disassembling the Solenoid and the Control Valve Mechanism
Use a long 17 mm spanner to open the fixing nut. When the fixing nut is released, make sure to free the clamp to be able to unscrew the fixing nut.
Remove the orifice plate.
Checking Components for Repair
Check the surface of the orifice plate, especially the area where the spindle closes to control return
Check the o- ring for cracks and wears.
Disassembling the Nozzle
Make sure the clamp the injector firmly to avoid damaging the nozzle pins.
Use the appropriate size socket adapter to be able to grasp the nozzle holder better. Use a long wrench to be able to exert force to release the nozzle holder.
Disassembling the Nozzle
Remove the nozzle, and make sure not to drop any small parts from inside the injector.
Disassembling the Nozzle
Remove the spring, adjustment shims, spacer, command piston etc.
Checking Components for Repair or Replacement
Check the surface of the nozzle needle for scratches. Nozzle needle wear is one of the main reasons for having a high return fuel.
Check the surface of the command piston, wear on the command piston is one of the reasons for having highreturn
Measuring and Setting the Spindle Sealing Tolerance
Reset the Dial gauge on a flat surface.
Measure the height difference between the spindle tip and the fixing nut.
The Sealing Tolerance must be min 0.03 mm
Assembling the Orifice Plate and the Solenoid Measuring and Setting the Spindle Sealing Tolerance
How to set Sealing Tolerance?
If the tolerance is lower than 0.03 mm, lap the fixing nut’s top surface with respect to its assembled position, slightly to adjust the tolerance.
Assembling the Orifice Plate Warning! Lapping process will leave metal dust on the components. Parts should be cleaned completely in the ultrasonic cleaning tank before assembling. Otherwise the metal dust will form an uneven thick layer on the solenoid and cause the injector seize or malfunction.
Place the orifice plate, with the cross formed leakage hole on the top.
Mount the fixing nut, and tighten using BA1426 Fixing Nut tool following tightening procedure and torque values specified below:
Initial Tightening: 45 Nm.
Release 60°; should release completely. Tighten with hand.
Final Tightening: 80 Nm in 90°.
Setting Air Gap Distance Measuring Height of the Solenoid
Place the Air Gap Setting Washer in the solenoid as shown in the figure.
Use the short extension provided with KO1519 Denso Air Gap Measuring Tool to measure the height of the Solenoid. Reset the dial gauge on a flat surface.
Aim the extension tip to the center of the solenoid and place the tool on the rim of the solenoid. Read the height as a plus figure. Note this height to calculate the air gap in the next step.
Setting Air Gap Distance Measuring the Magnet Plate Depth
Place the spindle into the center hole in the fixing nut.
Use the long extension to measure the magnet plate distance. Reset the dial gauge on a flat surface.
Aim the extension tip to the center of the spindle. Place the tool on the rim of the injector as shown in the figure. Read the depth as a minus figure from the level position. Note this value for calculating the air gap.
Calculating and Setting the Air Gap How to Calculate the Air Gap?
Air Gap= [Magnet Plate Depth]-[Solenoid Depth]
Example; Solenoid Height is measured +3.36 mm. Magnet plate depth is measured -3.46 mm.
The air gap is |3.46| - |3.36|=0.10 mm .
Denso Common Rail Injector (2 nd and 3rd Generation) Air Gap Setting is between 0.08 – 0.10 mm.
Change the thickness of the Air Gap Adjustment Washer to set the air gap distance.
What is the Affect of Air Gap and Spindle Sealing Tolerance
Spindle backlash needs a tolerance to be able to seal the orifice hole well, when running at high pressure.
On the other hand, Air Gap is critical to set the injection delay time, and also has an effect on fuel delivery at all pressure conditions.
Therefore these 2 dimensions are very critical to set before fine tuning the injection delivery.
Assembling the Solenoid
Place the o-ring for sealing solenoid assembly.
Make sure to place the solenoid shim inside the solenoid center hole. (Some models do not have shim; make sure to check the shim when disassembling!)
Place the spring carefully; making sure that the shim is flat inside the hole.
Assembling the Solenoid Warning! Never try to move the solenoid core back and forth in its sleeve. This will break the solenoid and cause the air gap change with respect to solenoid tightness.
Tighten the solenoid with hand and then follow below procedure to tighten the solenoid.
Final Tightening: 30 Nm.
Assembling the Nozzle For Pick-up and SUV applications
Clamp the injector on the KO1495 injector clamp before starting to assemble the nozzle. Place the command piston into the injector.
Place the nozzle spring tension adjustment shim.
Place the injector spring inside the injector.
Assembling the Nozzle For Pick-up and SUV applications
Place the centering piece onto the command piston.
Place the pins and the nozzle on the injector, mount the nozzle holder.
Place the appropriate socket adapter on the nozzle holder. Clamp the nozzle down to secure the pins.
Assembling the Nozzle For Pick-up and SUV applications
Nozzle Holder Tightening Procedure and Torque Values Initial tightening: 60 Nm. Release 120°. It should be completely loose. Tighten it with you hand. (3-7 Nm)
Final tightening: 45 Nm. It should be reached in 60°.
Assembling the Nozzle For Truck Applications
1 - Shim Support
2 - Spring Tension Adjustment Washer
Clamp the injector on the KO1495 injector clamp before starting to assemble the nozzle. Place the command piston into the injector.
Place the nozzle spring shim support then the nozzle spring tension adjustment shim into the injector.
Assembling the Nozzle For Pick-up and SUV applications
Nozzle Holder Tightening Procedure and Torque Values Initial tightening: 40 Nm. Release 120°. It should be completely loose. Tighten it with you hand. (3-7 Nm)
Final tightening: 65 Nm. It should be reached in 60°.
Fine Tuning the Delivery High Pressure Delivery Setting If the delivery is higher than limits; increase the air gap by 0.01 mm and increase solenoid adjustment shim by 0.01 mm.
If the delivery is lower than limits; decrease the air gap by 0.01 mm and decrease solenoid adjustment shim by 0.01 mm.
Warning! Make sure to check the delay time after changing the air gap. If delay time changes, Increase the thickness of the solenoid shim to increase the delay time, Decrease the thickness of the solenoid shim to decrease the delay time.
Fine Tuning the Delivery Low Pressure Delivery Setting If the delivery is higher than the limits; increase the nozzle spring adjustment shim by 0.02 mm.
If the delivery is lower than the limits; decrease the nozzle spring adjustment shim by 0.02 mm.
Warning! After changing the nozzle spring adjustment shim, make sure to repeat spray test at 200 bars. The nozzle should deliver fuel at 200 bars and it should not leak.
