REPAIRGUIDEFOR

DENSOCOMMONRAILINJECTORREPAIR

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DISCLAIMER

THEFOLLOWINGDOCUMENTISBASEDONTHERESULTSANDEXPERIENCEGAINEDFROMSTRIPPING,REBUILDINGANDTESTINGNEWGENUINEDENSOINJECTORSUSINGHARTRIDGEALLMAKESTESTEQUIPMENT.

THEINFORMATIONCONTAINEDWITHINISNOTINTENDEDFORUSEASASUBSTITUTETOTHEGENUINEDENSOREPAIRPROGRAM.ITSCONTENTISFORINFORMATIONPURPOSESONLYANDISTOBEUSEDASAGUIDEANDINTRODUCTIONTODENSOCOMMONRAILINJECTORREPAIR.

DIESELDISTRIBUTORSAUSTRALIAPTYLIMITEDANDDIESELDISTRIBUTORSLIMITEDINNEWZEALANDACCEPTSNORESPONSIBILTYFORANYDAMAGEORINJURYTHATMAYOCCURFROMTHEUNAUTHORISEDREPAIR/ADJUSTMENTOFDENSOCRINJECTORS.

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Introduction

TechnicalandrepairinformationsurroundingDensoCommonRailinjectorsoutsideoftheDensonetworkislimitedandscarce,yettheiruseandpresencewithintheAustralasiandieselmarketiswidespread.

Thefollowingdocumentaimstoprovideaguidetousingthetoolingandshimkitstogetherwithgenuineandnongenuineparts,tostrip,rebuildandtestDensoG2typecommonrailinjectors.Theinformationhereinhasbeengainedfromthedismantling,rebuildandconsequentflowandresponsetestingofnewDensoCRinjectorsusingtheHartridgeCriPCandIFT70allmakesprogramme.Alterationstotheshimadjustmentofindividualinjectorsweremadeandtheresultsrecorded.Theseresultshavebeenusedtodeterminewhateffectsanychangestotheshimadjustmenthaveontheoverallperformanceoftheinjector.

Correctioncodes(QRcodes)cannotbewrittenandproducedforanyDensoinjectorusingthisinformation.TheproductionandcreationofQRcodesrequirescomplexsoftwareandintricateflowtestingusinggenuineDenso/Hartridgeauthorisedequipment.DensoCRinjectorrepairinvolvesstringentcleanroompracticesandverytightqualitycontrolonbuildtolerances.PleasetakethisintoconsiderationwhenattemptinganydismantlingofDensoCRinjectors.

HopefullythisguidewillprovideaninsightintowhatcanbeachievedwithtoolingavailableoutsideoftheDensoofficialrepairprogramme.ConsiderationshouldbegiventotheimportanceofcorrectioncodeswhenundertakinganyadjustmentorunofficialrepairofANYcommonrailinjectorthatusesacorrectioncode.

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ComponentOverviewandIdentification:ThephotobelowshowsanexplodedstrippedDensoG2injectorandlabelledcomponents:

Solenoid

CalibrationShim

SolenoidSpringShim

SolenoidSpring

SolenoidValve

HalfBallValve

ValveSeatRetainingNut

ValveSeat

NOPShim

NOPSpring

PressureSpindle

CommandPiston

Nozzle

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DismantlingThefollowingdismantling,rebuildandtestinstructionsarebasedontheuseoftheCRinjectorkit(partnumber850901)andShimKits(850276,850296,850301)availabletopurchasefromDieselDistributors,togetherwithgenuineandnongenuinerepairparts.

STEP1SolenoidRemoval

Figure1 Figure2 Figure3

Mounttheinjectoruprightintheviceusingthecorrectholdingjaws,dependinguponthebodytypeandusingthe27mmcrowsfootgentlyloosenthesolenoid(fig1).OnceloosecontinuetoloosenbyhandandCAREFULLYandGENTLYremovethesolenoid,takingcarenottodropthesolenoidvalvespringortensioningshim(Fig2).

Removethefuelcalibrationshimthatwilleitherstillbesatontheinjectororsatupinsidethesolenoidbody(Fig2).

Thesolenoidvalvecanthenberemovedusinglongnosepliers.TAKECARENOTTODROPTHEHALFBALLVALVE(Fig3).Thisissituatedintheendofthesolenoidvalve.Itissmallandveryeasilylost!!(ReplacementvalvesandhalfballvalvesareavailablethroughDieselDistributors).

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STEP2ValveSeatRemoval

Figure4 Figure5 Figure6

InserttheThreeProngedValveSeatSocketintotheguide(Fig4),ensuringthatthe3prongsarelocatedinthe3holesinthevalveseatretainingscrewandthenscrewtheguideoverthesocket.Tightentheguideallthewaydownbyhanduntilitisfelttobottomout,thenunscrewbyapproximately1/8thofaturn(Fig5).Weneedtoensurethattheinner3prongedsocketwillturn,whilstmaintainingmaximumsupportfromtheguide,minimisingtheriskofthesockettilting.

WARNINGThisnutisusuallyverytight!.Useasuitablebreakerbaranda14mmsocketplacedoverthehexonthe3prongedsockettoundothevalveseatretainingnut(Fig6).Ifunsuccessful,useanelectricheatguntoapplyGENTLE,MODERATEheattothenut,thenusingthebrassdrift,strikethenutandretry.DONOTUSEABLOWTORCH!!Excessiveheatwilldamagetheinjector!

Figure7 Figure8 Figure9

Withthevalveseatremoved(Fig7),carefullyremovethe2locatingdowels(Fig8).Removetheinjectorfromtheholdingjigandturnupwards,whilstholdingyourhandovertheopenendofthebody(Fig9).Thecommandpistonshouldslideout,oratleastbegintoprotrudefromthebore.Withdrawthepistonfromthebody.Ifthereisnomovementofthecommandpistonatthispoint,itmaysignifythatitisseizedortight.Ifthisisthecase,thenitcanbeleftinsitutoberemovedafterthenozzleendhasbeendismantled.

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STEP3CapnutRemoval

Remounttheinjectorintheholdingjigwiththenozzleassemblypointingupwards.

Figure10 Figure11 Figure12

Aswiththevalveseatretainingnut,thenozzleretainingnutcanalsobenotoriouslytight.Onemethodthatcanbeusedtoremovethenutmoreeasilyandminimisetheriskofdamagetothebodythreadandlocatingdowelsinvolvestheuseofapipecuttertoscorethecapandfreethethreadpriortoremoval.ItiscommonpracticetorenewthecapnutonCRinjectorsanyway,sothecapnutwillhavetobediscardedandanewone(availablefromDieselDistributors)willbefittedonrebuild.

Toremovethecapnut,scorealinenodeeperthan0.5mmapproximately15mmfromthebaseofthenut(oppositetonozzleside)aroundthecapnut(Fig10).Then,usingagood15mmsinglehexsocket,undothenut.Thereisa15mmcrowsfootsuppliedinthekit,butthisisbestreservedfortightening,ifusinganinjectoraligningjig.

Oncetheinjectorcapnuthasbeenremoved,thenozzlecanberemovedalongwiththelocatingdowels(Fig11).Finally,removetheinjectorbodyfromthejigandcarefullyturnover,whilstholdingtheneedlespringandremovethespringandspringtensioningshim(Fig12).

Ifthecommandpistonwasnotremovedearlierduetobeingtightorseized,thenitcannowbegentlytappedoutfromoneend.USUALLY,IFTHECOMMANDPISTONREQUIRESFORCETOBEREMOVED,THEINJECTORBODYANDPISTONCANBECONSIDEREDUNSERVICABLEANDNOTWORTHREPAIRING.

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InspectionSolenoidassembly

Figure13

Resistancechecksshouldbemadetothesolenoid.Thespecificresistancemeasuredwilldependuponthetypeofinjectorandshouldbecomparedtoanewunit.TheresistancerecordedontheparticularG2injectorsthatwetestedwasapproximately0.50.7Ohms.

Obvioussignsofanydamagetotheoutercasingorsplits/cracksontheelectricalconnectorshouldbeobserved.Checkforerosion/corrosionoftheelectricalterminalsandensurethattheinnersurfaceofthesolenoidiscleanandfreefromdentsetc(Fig13).

Ensurethatthesolenoidspringisingoodcondition.Itmaybeagoodideatocheckandrecordthelengthagainstanewone.

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SolenoidValveandHalfBallValveassembly

Figure14

Checktheconditionofthesolenoidvalveassembly,payingparticularattentiontothehalfballvalvefaceandtheseatinsidethevalvestem.Theflatfaceofthehalfballvalveisresponsibleforsealingthecontrolchamber,soitmustbeingoodconditionwithnoerosionorwear.Thesecomponentsarebestinspectedunderamicroscope.Checktheconicalseatthattheballseatsoninsidethevalve,aswellasthevalvestemforanysignsofwear,scratchesanderosion(Fig14).

Renewbothcomponentsifthereareanyabnormalitiesordoubtontheircondition(bothavailablefromDieselDistributors).

Inspectball,seatandshank

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ValveSeatandRetainingNut

Figure16

Inspectthevalveseatforerosionandwear(Fig16).Aswiththeballandvalveassembly,thisisprobablybestviewedunderamicroscopeorothermagnificationequipment.Ifthereareanymarksacrosstheseatingareathatwouldsuggestasealingproblemrenewthevalveseat(availablethroughDieselDistributors).

Inspectthesealingfaceoftheretainingnutforsignsoferosionandwear(Fig16).

DuetotheveryfinetolerancesinvolvedinCRinjectors,lappingofthesealingsurfacesofthesecomponentsisnotrecommended.AnyattempttolapthesurfacesshouldbeundertakenwiththeutmostcareandwiththeuseofVERYFINElappingpastes.

Inspectallsurfacesforerosion&wear

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CommandPiston&InjectorBody

Figure17

Checkthepistonforscoringandwearmarksalongwiththeinnerboreoftheinjector.Ifthereisconsideredtobeexcessivescoringorwearoneithercomponent,thentheunitwillmorethanlikelybescrapped(Fig17).Thepistonshouldbeclean,freefromscoringandmovefreelyinsidetheinjectorborewithnosnaggingortightspots.

NozzleAssembly,PressureSpindleandSpring.

Guidelinesforinspectingthenozzleassemblycanbeconsideredthesameasforanyconventionalnozzle.Checkforexcessivewearorscoringontheneedleshankandseatandrenewthenozzleifnecessary.(GenuineandnongenuinenozzlesareavailablefromDieselDistributors,dependinguponapplicationandavailability).

Checkthespringforconditionandthespindleforexcessivewearonthespringseat.

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ReAssemblyWhenreassemblinganycommonrailcomponents,cleanpracticesshouldalwaysbeobservedandtheutmostprecautionshouldbetakentoavoidanycontaminationofthecomponentsbeforeandduringassembly.

WARNINGThetorquevaluesmentionedinthefollowingprocedureareaSUGGESTEDVALUEbaseduponourexperienceandNOTDensospecification.

STEP1.2ValveSeatAssembly

Figure18 Figure19 Figure20

Mounttheinjectorintheholdingjigandplacethe2locatingdowelsintotheirboresonthetopfaceoftheinjector(thesedowelsarelargerinlengthanddiametertothenozzlelocatingdowels).Ensurethatthevalveseatisthecorrectwayroundbeforeinsertingitintotheinjector.Theboreontheundersideofthevalveneedstobealignedwiththeboreholeontheinjectorface(Fig18&19).

Usingthe3prongedsocket,insertandhandtightentheretainingnutintotheinjectorwiththesealingfacetowardsthevalve.Screwtheguideoverthesocket,ensuringthatthesocketcanstillmove,butwithmaximumsupportfromtheguideandtightento7075NM(Fig20).

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STEP2.2Solenoid&SolenoidValveAssembly

Figure21 Figure22

Fitthehalfballvalveintothesolenoidvalvestemandensurethattheflatfaceofthehalfballvalveisvisibleandlevelwiththestem.DONOTINSERTTHEVALVESTEMINTOTHEVALVESEATIFYOUCANSEETHESPHERICALPARTOFTHEHALFBALLVALVE(Fig22).ITMUSTBETHEFLATSIDE(Fig21).

Figure23 Figure24 Figure25

Thehalfballvalveshouldstayinthevalvestemwhenturnedoverandinsertedonthevalveseat.Oncethevalvestemisinpositionensureitisfreebyrotatingit(Fig23).

Placethefuelcalibrationshimontopoftheinjector(Fig24).

Next,insertthesolenoidspringshimandsolenoidspringintothesolenoidandcarefullyfitthesolenoidontotheinjector,ensuringthatthespringseatsinthecentreofthevalveandhandtighten.Oncehandtight,tensionthesolenoidassemblyto1012NM(Fig25).OVERTIGHTENINGOFTHESOLENOIDASSEMBLYCANHAVEANADVERSEAFFECTONTHEOPERATIONOFTHEINJECTORANDMAYRESULTINDAMAGETOTHESOLENOID.

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STEP3.2NozzleandCapNutAssembly

Figure26 Figure27 Figure28

Repositiontheinjectorassemblyinthejigwiththesolenoidtowardsthebottom.

Insertthecommandpistonintotheinjectorbodywiththemainshankmachinedwithgroovestowardsthesolenoidend(Fig26).

Nextinsertthenozzleopeningpressureshimandthespringintothecentralinjectorboreandtheninsertthepressurespindleontopofthespringwiththesmallerdiameterfacingthenozzleneedle(Fig27.)

Insertthelocatingdowelsintothesealingfaceandplacetheinjectoroverthem.Placethe(new)capnutoverthenozzleandscrewdownuntilhandtight(Fig28).

Ideallysomekindofinjectorclampingrigshouldbeusedtounsurealignmentofthenozzle,ifyoucanfindsomethingormanufactureanythingsuitabletoholdthebody.Thearrangementpicturedbelow(Fig29)featurestheStanadyneInjectorAligningTool(Part#29617).Aninjectoraligningtoolwasnotusedinthisexerciseandnooperationalproblemswereexperienced,howeveritwouldbebettertouseoneifavailabletominimisetheriskofmisalignmentorbreakingthedowelpins.

Figure29

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TestingAlltestingoftheDensoCRinjectorsusedtoobtaintheinformationgivenherewascompletedusingtheHartidgeCRIPCandtheIFT70.(bothavailablefromDieselDistributors)

WhentestingDensoCommonRailinjectorsthefollowingelementsshouldbeobservedtoevaluateanddeterminethefunctionalityandconditionoftheinjector:

1Nozzleopeningpressure 2InjectorResponseTime 3FuelDelivery 4Backleakage 5Backleakagetemperature

Eachoftheabovewillbediscussedinmoredetailinthefollowingguidewhichhopestoprovideanunderstandingofwhateffectalteringtheshimadjustmenthasontheinjectorsperformance.

1. NozzleNeedleopeningpressureThiscanbesetbytheshimthatsitsbehindthenozzlespring.ThenozzleopeningpressuresettingonaG2injectorwillhaveaneffectonfueldeliveryandResponseTime(seefurtherdowninsection2fordefinition)particularlyatlowerenginespeedsandrailpressures.Iftheopeningpressureissettoolow,theidledeliveryandpreinjectionwillincrease.Iftheopeningpressureissettoohightheidleandpreinjectionwilldecreaseandresponsetimewillincrease.Fuellingandresponsetimeatmainfuellingsettingswillremainlargelyunaffected.WecansettheopeningpressurewiththeuseofaHartridgeIFT70injectorfunctiontesterthatcanactuatethesolenoidwhilsttheusercanobservethespraypatternandcontroltherailorfeedpressure.ThisexercisecouldpossiblybeperformedwithaconventionalinjectortesterandamultifunctionCRinjectortriggerboxsuchastheIFTC(availablefromDieselDistributors).THISTESTSHOULDBECARRIEDOUTANDSET(IFNECESSARY)BEFOREANYFLOWTESTINGOFTHEINJECTOR.

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Mounttheinjectorintothemachineandconnectthehighpressurepipeandappropriateelectricalconnector.

Figure30 Figure31

Usingalargepulsewidthofaround2.5m/sandlowinjectionspeedofsay100injectionsperminute(IPM)(Fig30).Setthefeed(railpressure)tozeroandgraduallyincreaseuntilthefuelcanbeseentoinject.Atthispointtakenoteofthepressureonthegaugeatwhichinjectionstartedtotakeplace.(Fig31).

TheopeningpressureontheparticularDensoinjectortestedwasapproximately130140bar.Thisfiguremaydifferdependinguponinjectorpartnumber.Itwillbeuptotheusertogainsomespecificationsfromnewinjectors.

Ifthepressureneedstobeadjusted,thentheopeningpressureshimwillneedtobechangedtoincreaseordecreasespringtensionaccordingly.Sincethenozzlecapnutwillnothavebeenputintoservicethelooseningandretensioningshouldnotcauseanyissuesandshouldbeabletobereusedafterremoval.

AcheckofthespraypatternandgeneraloperationoftheinjectorcanthenbeperformedwhilststillmountedontheIFT70aftertheopeningpressurehasbeenchecked.Asageneralrulethereshouldbenomorethan3040%backleakagedeliverycomparedwithfueldeliveryonfullloadsettings(e.g.500bar1200PPM1.2m/spulsewidthwhenusingtheIFT70).

Iftheinjectorisfunctioningproperlywithbasicdelivery,backleakageandspraypatternallsatisfactory,theinjectorcanbeflowedmoreaccuratelywiththeHartridgeCRIPCorAVM2withCRinjectorallmakescapableofcheckingfueldelivery,backleakageandresponsetimeathighpressures(1600bar+).

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2. ResponseTimeSimplyexplainedthisisthetimetakenfromwhentheECUsendsasignal(current)totheinjectortowhentheactualinjectiontakesplace.Itisanimportantfactorindeterminingtheconditionoftheinjector.Ingeneralincreasedresponsetimepointstowardsapoorlyfunctioninginjector.Onvehicleeffectsofpoorresponsetimecanshowaswhitesmoke,roughrunning,idlingproblems,detonation(knocking)andpoorperformance.InjectorresponsetimeisanimportantfactorfortheECUtobeabletocompensatedrivepulseforrecalculatingfuelquantitiesforonvehiclelearningofQRcodes.Responsetimecanbeaffectedbyopeningpressure,commandpistoncondition,nozzlecondition,solenoidvalveconditionandsolenoidefficiency.Anythingthatcaneffectivelyslowdowntheoperationoftheinjectorwillresultinincreasedresponsetime.Ifresponsetimecanbereadandseenthenaclearerpicturecanbegainedfromtheinjectortestonthegeneralconditionoftheinjector,asopposedtoonlyrelyinguponmeasuringdeliveryandbackleakage.Itcanbeconsideredimportantinourdiagnosisofinjectorcondition.Itcanbeaffectedbychangingfuellingshimsandopeningpressure.TypicalresponsetimesrecordedfortheDensoinjectorstestedwereintheregionof430490sforhigherpulsewidthandpressuresettings(fullandmidloadscenario).Responsetimewillgenerallyincreaseatidleandlowerpulsewidthsandpressures(idle,partloadandpreinjection).Typicalidleresponsetimesmaybearound490560s.Again,theabovefiguresarebaseduponthetestingofcertainDensoinjectorsandtogainamorethoroughunderstandingofinjectorspecificresponsetimefigures,newinjectorswouldneedtobetestedandresultsrecorded.

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3. FuelDelivery

AftertheopeningpressurehasbeensetandtheinjectorhasbeentestedforbasicfunctionitcanthenbeproperlyflowedforamoreindepthtestontheHartridgeAVM2PCwithinjectorallmakeskitortheHartridgeCRIPC.

Theinjectorneedstobegivenatestplanofsettingsfromwhichtheresultscanberecorded.Thesevaryingsettingsshouldputtheinjectorthroughdifferingtestsituationsthatwouldbestsimulatevariousengineconditions.Anexampleofthesetestconditionshasbeenincludedbelowforreference:(Fig32).

Figure31TestPlanExample

Onceasetoftestsorconditionshavebeendecidedupon,theycanthenbeusedasagenerictestplanforalmostallinjectors.Thetestplanisthenusedtorecordtheresultsfromnewinjectorsandusedforcomparisonagainstusedorrepairedunits.Adatabaseofresultscanbebuiltupandtolerancescanevenbeformedbytestingmultiplenewunitsandtakingaveragereadings,fromwhichtolerancebandscanbedecided.

IftheflowresultsfromausedorrepairedinjectoraredeemedtobeoutofspecwhencomparedtoatestresultfromanewinjectorthenthefueldeliverycanbealteredbychangingtheCalibrationShimwhichsitsinbetweenthesolenoidandtheinjectorbody.CHANGINGTHISSHIMWILLHAVEANEFFECTONTHEOVERALLFUELDELIVERYOFTHEINJECTOR.

ToINCREASEthefuellingaTHICKERshimmustbefitted

ToDECREASEthefuellingaSMALLERshimmustbefitted.

TOYOTA236700L090BEFOREADJUSTMENTInjector#

Pressure(bar) SpeedPulsewidth(s)

Deliveryml/st

BackLeakml/st

Response(s) ReturnTempC

Idle400 350 750 12.4 14.9 489 39MidRange1000 800 800 49.3 22.8 432 40FullLoad1600 1500 1000 95.2 33.8 418 50StaticLeak1600 1000 0 0 0 0 52PreInjection600 1000 500 9 14.7 452 49MidRange800 1200 800 39.9 19.6 446 51Start950 150 1000 64.2 105.6 551 48

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0.1mmdifferenceinshimsizewillequatetoanapproximate7%changeinfuellingacrossthewholerangeoftheinjector.However,theresponsetimewillalsochangeaswehaveeffectivelychangedthetotaldistancethatthesolenoidvalvehastotravel.Inanefforttocounteracttheresultingresponsetimechange,thesolenoidspringshimcanbechangedtotryandlimittheresultingdifferenceinresponsetime.Althoughadifferenceinresponsetimeisseenwhenthesolenoidspringshimischanged,itisminimalanddoesnotreturntotheoriginalresultsafteramaincalibrationshimalteration.

Itwouldthereforebeprudenttomakeonlysmallalterationstothecalibrationsettingwhenconsideringanychangestothefuellingoftheinjector.

Changingthesolenoidspringshimwillalsoaffectfueldeliveryaswellasresponsetime,aswearereducingorincreasingspringtensiononthesolenoidvalve,makingiteasierorharderforthesolenoidtopullupthevalve.Again,considertheeffectstothefuellingthroughouttherangewhenattemptinganyshimadjustment.

4Backleakage&BackleakTemperature

TheamountofbackleakagefuelthataCRinjectorproducesisanindicatoroftheinternalsealingandconditionoftheinjector.Anyproblemswiththesealingofthesolenoidvalveorthenozzleneedlewillshowupashighbackleakage.Usually,ifhighbackleakageisexperienceditwillbeseenineverytestandcanindicatevalveseatproblems,solenoidvalveproblemsandnozzlesealingorwearissues.

Backleakagetemperatureisalsoworthmonitoring,asanyexcessiveleakageofhighpressurefuelwithintheinjectorwillcausethetemperatureofthebackleakagetorise.Thisisbecausethehighpressurefuelcreatedintherailisalothighertemperaturethanthelowerpressureofthebackleakage,thereforeanyexcessiveriseinbackleakedfuelwillshowupasahighbackleaktemperature.

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CorrectionCoding&BatchingCRinjectorcorrectioncodingisimportantandallowstheCRsystemasawholetocompensateformechanicalandhydraulictoleranceswithintheinjector.NotwoinjectorswillnaturallyflowthesameandthevehicleECUcancompensateforthisbyalteringthepulsewidthtoindividualinjectorswhenthecorrectioncodegiventotheinjectorduringmanufactureisprogrammedintotheECU.

Wecannotproducethiscodewithconventionalallmakesequipment.ItrequiresaconsiderableinvestmentandOEMbackingtodoso.

Onemethodoftryingtolimittheproblemofourinabilitytoproduceanindividualcorrectioncodeistobatchinjectors.Thismethodinvolvesflowtestingandadjustingthefueldeliveryoninjectorssothatthedifferencesbetweenthemareminimal.Sayforinstancewehadaround30injectorsthatwererepairedandflowtested.Thebatchingconceptassumesthatoutofthose30injectorstherewouldbesetsthatwoulddisplaysimilarflowandresponsecharacteristics.Theseinjectorscouldthenbefurtherfinetunedwithminoradjustmenttomakethemassimilartoeachotheraspossible.

Setsof4or6injectorsarethensoldorfittedtogethertominimiseanymajordifferencesinflow.

Anotherconceptistobuildlengthydatabaseontheflowratesofdifferingnewinjectorsfromsamepartnumberfamilybyrecordingtheirflowandresponsecharacteristicsandthecodeonthatparticularinjector.Overtimeadatabasecanbebuiltandanyfutureinjectorsthatdisplayedsimilarresultstoapreviouslyrecordedunitwouldbegiventhecodefromthatsimilarflowingnewinjector.Thiswouldbealongandcomplicatedprocess,butnotimpossible.

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SUMMARY

Thereareparts,testequipmentandtoolingavailablethroughDieselDistributorstoserviceandtestDensoCRinjectors.Thereisnoconcretesetofinstructionsortestdatatoproduceaperfectlyrepairedproduct.Thereishowever,anopeningtobeabletooffersomethingmorethanjustanewunitinbox.

Therepairconceptofferedhereistoenabletheusertheabilitytolearnasyougoandbaserepairsondataobtainedfromnewunits.

Hopefully,theinformationinthisdocumentisenoughtogetyoustarted.

Forfurtherinformationpleasecontact:

DieselDistributorsAustraliaPeterHunterpeterh@ddal.com.au

DieselDistributorsNewZealandKevinMorriskevin@dieseld.co.nz