Denso Common Rail Injector

Repair
 Training Outline
 Recommended Tools
 Description of Components,
 Disassembly, Visual Checks,
 Assembly
 Fine Tuning the Delivery
Recommended Tools
KO1521 – Denso Repair 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
9 Injector Body 18 Nozzle Holder
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
figure.
 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 (2nd 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.
Fine Tuning the Delivery
Middle Load-Middle Pressure Delivery Setting
If the middle load delivery is higher than the limits; increase the solenoid spring
adjustment shim by 0.01 mm.
If the middle load delivery is lower than the limits; decrease the solenoid spring
adjustment shim by 0.01 mm.
Warning!
After changing the solenoid shim thickness, check the delay time. If the delay
time is changed,
Increase the air gap to increase the delay time,
Decrease the air gap to decrease the delay time.