Debugging step for common rail injector range

CRIN1:

11.Armature lift adjusting shim

2 Remaining air gap adjusting shim

3, Nozzle lift adjusting shim

4 Nozzle pin valve spring force adjusting shim

5 Solenoid valve spring force adjusting shim 6 Circlip

7 The armature total range adjusting circlip

1. The armature total range: (Standard values: 85-95um)

Pull down solenoid valve, remove the ball and seat, put armature parts and adjusting shim, put the small bush with
opening, and screw the small bush on, fit gauge stand adaptor. amesdial and pins, fix the amesdial and ensure good
amesdial sliding and amesdial shows "zero", gently press the top of the meter axis with fingers, what it displays now is:
armature total range.
2. The armature lift: (standard value: 45-50um)

Load the ball and seat properly into the small bush with an opening, screw the small bush with an
opening on, and then screw on gauge stand adaptor, fit on amesdial and probe, fix the amesdial and
ensure good amesdial sliding and amesdial shows "zero", gently press the amesdial top with fingers,
what it displays now is: armature lift.

3. Remaining air gap: (standard value: 35-55um)

3.1 Remove the solenoid valve springs and shim, put armature into solenoid valve, pls do not put air gap lift
shim at this time, smooth test normalized "zero"

3.2 Remove armature, put the air gap shim into do test, what it displays now is: air gap lift.
After you displace the valve assembly:
Test nozzle pin valve lift, which decides nozzle pin valve shim thickness (Horsepower different)
Test armature total range, which decides circlip thickness
Test armature range, which decides the hexagonal shim thickness below.
Test remaining air gap, which decides the hexagonal shim thickness above.
If VE is not proper, pls debug solenoid valve spring force adjusting shim.
If LL is not proper, pls debug nozzle pin valve spring force shim.

CRIN2:

1: Armature lift adjusting

shim
2, Cross lift adjusting shim
3, Nozzle pin valve lift
adjusting shim
4, Nozzle pin valve spring
force shim
5. Solenoid valve spring
force adjusting shim

1. Armature lift test (standard value: 45-50um)

 Remove solenoid valve Insulation barrier using special tool, remove the plug and remove the steel ball,
remove the solenoid valve, take electromagnet spring and shim out, and then fit on solenoid valve, firstly use the probe
downward pressure to check if there is a gap or not, as no clearance pls check ball valve assembly is correct or not,
choose to use correct test joints & tighten the solenoid valve according to 《standard torque》, fit on gauge standard
adaptor and the longest probe, push amesdial pin to ensure slide freely. Repeatedly press amesdial axis lightly after
you make the amesdial shows zero, the reading now is: armature lift.

2. Cross lift test steps (standard value: 35-50um):

Step 1: Remove the solenoid valve, remove the valve ball and seat, return spring. Fit on armature and
cross lift shim, fit on amesdial & adaptor using spherical gaugehead, place on injector and recognize
normalized "zero.

Step 2: Remove gauge, armature assembly and cross lift shim, fit on valve ball, ball seat, armature
assembly and cross lift shims to test and confirm the reading, that is: cross lift datum.

3. Remaining air gap testing: (standard value: 35-55um):

The excircle of electromagnet end face is armature clamping surface, and the excircle is higher than the
inner ring surface, this height difference is the remaining air gap, choose proper adaptor, fitted spheric
gaugehead, and adjust it to show “zero” on flat surface, make it close together solenoid valve end
surface, the testing data of gaugehead aiming at the inner ring surface to test is “Remaining air gap”.

4. Injector pin valve lift and wear measurement:

Choose gauge stand adaptor and pin, make it show zero on flat surface, test nozzle pin valve sinking
size, load spring, shims, ejector rob and maximum injection adjusting shim, use amesdial to test
distance between this height and injector end face, plus nozzle pin valve sinking size, that is pin valve
lift, and the size of pin valve lift is the amount of max injection, without influence to other fuel capacity.

CRI injector：
 1：Armature lift adjusting shim
2：Remaining air gap adjusting shim
3：The armature total range adjusting
circlip
4 ： Solenoid valve spring force
adjusting shim
5 ： Nozzle spring force adjusting
shims

1. Armature lift (standard value: 45-45um)

Remove solenoid valve, remove solenoid valve springs, shims, remaining air gap shims, put a small
bush with openings into, screw the pressure cap with opening and screw it down according to <stand
torque>, fit on adaptor and amesdial, make sure amesdial slide well and shows zero, gently press the
top of the meter axis with fingers, repeatedly press a few times to ensure accurate accuracy, what it
display now is: Armature lift.
2. The armature total range: (Standard values: 55-70um)

Remove the small circlip, remove the armature plate, spring, using special tool to dismantle valve assembly
pressure cap, remove the armature assembly, ball valve and ball valve base, fit on the armature assembly and lift
shims, screw down valve assembly pressure cap according to <stand torque>, fit on the armature plate, spring
and circlip in order. Fit on a thick shim, and put the bush with opening into, screw the pressure cap with opening
and screw it down according to <stand torque>, fit on adaptor and amesdial, make sure amesdial slide
well and show zero, gently press the top of the meter axis with fingers, repeatedly press a few times to
ensure accurate accuracy, what it display now is: The armature total range.

3.Remaining air gap: (standard value: 35-55um)

Remove the solenoid valve, put into remaining air gap shim, choose proper gauge stand adaptor and measuring
pin, make amesdial show zero on flat surface.

3.1 Now test the distance between armature plate and remaining air gap, to test again after changing the angle to

make sure accuracy, and make a record for the data.

3.2 Test the distance between remaining air gap and electromagnet, to make adaptor surface close together

with solenoid valve end face when testing. Use the data to subtract the data tested by first step is remaining
air gap.
DENSO
Armature lift: (standard value: 45-55um)

1. Dismantle solenoid valve, choose adaptor, flat head measuring pin and amesdial, and make the amesdial
show zero on flat surface, put the armature lift shim on the injector, make amesdial back and forth rotation to
ensure the stability test, make a record for the data.

2. Choose standard adaptor and make it show zero on flat surface, make the gauge stand adaptor surface close
together in the end face of the solenoid valves on the solenoid valve, put meausring pin in from gap of solenoid valve
side to the bottom and to test several points to make sure testing accuracy, and make a record for the data. Use this
data subtract the data in step 1 is armature lift.
 Common rail injector test steps and the impact to the engine

LEAK TEST: This test verifies that leakage of valve assembly, high pressure sealing ring, nozzle pin
valve pressure cap part.
VL Max injection amount: too large injection will bring smoke and large fuel consumption; too small
injection amount will make the vehicle powerless and slow to speedup. The tolerance each
injector should be controlled within 6mm3/HH when adjusting, which is mainly adjusted
through nozzle lift shims.
TL/EM medium speed / emission point fuel amount: fuel injection characteristics verification point, excessive
injection will bring smoke and emission exceed the standard; too small injection amount will make the vehicle
powerless and slow to speedup. This is decided by nozzle spring force shims, armature lift, cross lift adjusting shims
and solenoid valve spring force shims.
LL idle fuel amount: excessive idle will bring smoke, too small will lost throttle and flameout, start-up difficulties, fuel
amount unevenness will lead rotation speed do not stabilize, noise, and the engine swings during speedup.
Unevenness should be controlled within 2mm3/HH, which is mainly adjusted by nozzle spring force shims.
VE pre-injection fuel amount: too large the fuel will knock cylinder and bring smoke, too small will make large noise,
start-up difficulties and powerless to speedup. Unevenness should be controlled within 0.5mm3/HH,
which is mainly adjusted by solenoid valve spring force shims.

Remarks: The premise of the above adjustment method is various range adjusted within its scope.