2020 / 10

Workshop Manual
Common Rail Injectors (DFI)

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Repair Procedure 02 11o
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 Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.
Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.
Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie sofort reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its productrange.
einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen. All Rights Reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,
Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores, recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.
tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar la
piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel,
consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad.

Do not put your skin into the fuel jets under pressure, especially those due to pressure
pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injection
under the skin, contact a doctor immediately. Please refer to the health and security fuel
documents. Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd., mais
la société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd. poursuit un programme intensif de conception et de développement
Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux qui peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd. se réserve le droit de modifier les spécifications, sans pré-
provenant des fuites de tuyaux et des joints soumis à la haute pression. Le liquide sous avis et si cela est nécessaire, pour assurer les performances optimales de sa gamme de produits.
Tous droits réservés
haute pression injecté sous la peau peut causer des blessures mortelles. En cas
Toute reproduction, mémorisation dans un système informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen électronique,
d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de mécanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation préalable de Delphi Diesel Systems Ltd.
santé et de sécurité du gazole.
Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione,
specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione

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possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare

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immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

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Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen

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Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità per
onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder eventuali imprecisioni. Delphi Diesel Systems Ltd. svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto.
hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als
02 o Delphi Diesel Systems Ltd. si riserva il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini assicurare le prestazioni

-
de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezon- ottimali dalla sua gamma di prodotti.

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dheids-en veiligheidsfiche met betrekking tot de brandstof.z Tutti i diritti riservati
Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo,
Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a elettronico, di fotocopiatura, di registrazione o altro, senza previa autorizzazione di Delphi Diesel Systems Ltd.

9-
fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentos
04 nce

mortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte

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or favor a documentação respeitante a saúde e segurança de combustíveis.

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Schutzbrille/Gesichtsschutz tragen. Proteggersi gli occhi/la faccia.

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va

Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd. no acepta ninguna responsabilidad legal
por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd. se sigue un programa intensivo de diseño e investigación el cual podría

iV
Úsese protección para los ojos/la cara. Veiligheidsbril/-masker gebruiken. en cualquier momento alterar la especificación de los productos. Delphi Diesel Systems Ltd. se reserva el derecho de alterar las especificaciones
sin notificación previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos.
Ad

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Todos los Derechos Reservados
Wear eye/face protection. Use protecção da face/olhos. No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia,
grabación o cualquier otro, sin autorización previa de Delphi Diesel Systems Ltd.
el
Porter un appareil de protection
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des yeux / du visage.

Von Zündquellen fernhalten Conservare lontano da fiamme

- Nicht rauchen. e scintille - Non fumare.
Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel Systems
Conservar alejado de toda llama Ver van open vuur en ontstekingsbronnen Ltd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein forlaufendes Design
o fuentede chispas - No fumar. houden - Niet reken. und Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produkdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne
Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen.
Alle Rechte vorbehalten.
Keep away from sources of ignition Mantenha afastado de fontes
Kein Teil dieser Veröffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystem
- No smoking. de ignição - Proibido fumar. gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopiren, Aufzeichnen oder auf sonstige Art,
übertragen werden.
Conserver à l'écart de toute flamme ou
source d'étincelles - Ne pas fumer.

Geeignete Schutzhandschuhe tragen. Usare guanti adatti.

Ainda que se tenha lido o máximo cuidado na compilação da informação contida nesta publicação, a Delphi Diesel Systems Ltd., não pode aceitar qualquer
Aangepaste veiligheidshandschoenen responsabilidade legal por inexactidões. ADelphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento qe pode porventurau
Usen guantes adecuados. alterar as especificações do produto. ADelphi Diesel Systems Ltd. reserva o direito de alterar especificações sem aviso e sempre que seja necessario
dragen
para assegurar um desempeho óptimo da sua linha de produtos.
Todos os direitos reservados.
Wear suitable gloves. Use luvas apropriadas. Nenhuma parte desda publicação pode se reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por
quaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.

Porter des gants appropriés.

 TABLE OF CONTENTS

INTRODUCTION I

DIAGNOSTICS / CLEANING II

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DISMANTLING / REASSEMBLY III

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AFTER THE REPAIR OPERATION IV
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APPENDICES V
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Produced and published by:

Delphi Technologies
Wireless House Tel: +44 (0) 1926 470000
© BorgWarner Inc.

Warwick Technology Park Fax: +44 (0) 1926 472000

CV34 6DW Warwick
UK [Link]

DDNX299G(EN) - Issue 1 of 10/2020 i

Delphi Technologies is a Brand of BorgWarner Inc.
I IN TRODUC TION

TABLE OF CONTENTS

1. INTRODUCTION
1.1 Forward.................................................................................................................................................................................1-1
1.2 Important Recommendations ...........................................................................................................................................1-2
1.3 Injector Identification ........................................................................................................................................................1-3
1.4 Internal changes to the injector.......................................................................................................................................1-6
1.4.1 Change Valve CVA => SVA ............................................................................................................................... 1-6
1.4.2 Coil changes ....................................................................................................................................................... 1-7

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 DIA GN OS TIC S / C LEA N ING II

TABLE OF CONTENTS

2. DIAGNOSTICS / CLEANING
2.1 Vehicle Symptoms and Rapid Diagnosis..........................................................................................................................2-9
2.1.1 Vehicle symptoms............................................................................................................................................. 2-9
2.1.2 Diagnostics before dismantling the injector..............................................................................................2-10
2.1.3 Diagnostic harness: ........................................................................................................................................2-11
2.1.4 Repair harnesses.............................................................................................................................................2-11
2.2 Cleaning ..............................................................................................................................................................................2-13
2.2.1 Preliminary cleaning .......................................................................................................................................2-13
2.2.2 Ultrasonic cleaning .........................................................................................................................................2-18
2.2.3 Rinse cleaning ..................................................................................................................................................2-19
2.2.4 Application .......................................................................................................................................................2-20
2.3 Test Bench Diagnostics ....................................................................................................................................................2-20
2.3.1 Electrical tests.................................................................................................................................................2-20
2.3.2 Static leakage test..........................................................................................................................................2-21

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2.3.3 Dynamic leakage test .....................................................................................................................................2-22

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2.3.4 Fuel deliveries and opening delays..............................................................................................................2-22
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III DIS M A N TLING / REA S S EM BLY

TABLE OF CONTENTS

3. DISMANTLING
3.1 Introduction .......................................................................................................................................................................3-23
3.1.1 Injector repair - when to apply (other than special agreements) ..........................................................3-23
3.1.2 Faults and replacing parts.............................................................................................................................3-23
3.1.3 Description of parts........................................................................................................................................3-24
3.2 Tools....................................................................................................................................................................................3-24
3.3 Preparation for dismantling............................................................................................................................................3-43
3.4 Repair Equipment upgrade..............................................................................................................................................3-43
3.5 Fitting the injector on the support ................................................................................................................................3-43
3.6 Identification support ......................................................................................................................................................3-44
3.6.1 Adhesive label .................................................................................................................................................3-44
3.6.2 Plastic code plate ............................................................................................................................................3-45
3.7 External Parts....................................................................................................................................................................3-46
3.7.1 External gland nut - Ford Puma....................................................................................................................3-46

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3.7.2 External gland nut - Yuchai 4W ....................................................................................................................3-46

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3.7.3 Injector capnut ................................................................................................................................................3-48
3.8 Internal Parts.....................................................................................................................................................................3-56
3.9 Edge / Mesh filter - DFI1.5...............................................................................................................................................3-56
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3.10 Connector DFI1.20 / DFI2.20............................................................................................................................................3-62
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3.11 Connector "AK" - DFI1.20.................................................................................................................................................3-64
4. REPLACEMENT
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4.1 Preliminary operations ....................................................................................................................................................4-67

4.2 Replacing parts..................................................................................................................................................................4-68
4.2.1 Fault table ........................................................................................................................................................4-68
4.2.2 Replacement procedure .................................................................................................................................4-69
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5. REASSEMBLY
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5.1 Precautions before Assembly .........................................................................................................................................5-71

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5.2 Injector Assembly .............................................................................................................................................................5-71

5.2.1 Mesh filter - DFI1.5 .........................................................................................................................................5-72
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5.2.2 Connector "AK" - DFI1.20...............................................................................................................................5-78

5.2.3 Valve spring and calibration pin ...................................................................................................................5-78
5.2.4 Valve / adapter plate assembly or CVA or SVA..........................................................................................5-80
5.2.5 Internal component assembly ......................................................................................................................5-81
5.2.6 Tightening the capnut....................................................................................................................................5-82
5.2.7 External components .....................................................................................................................................5-87
5.3 Replacing the identification label ..................................................................................................................................5-89
5.3.1 Adhesive label .................................................................................................................................................5-89
5.3.2 Adhesive label- DFI2.5 HPC / 2.5.2 HPC .......................................................................................................5-90
5.3.3 Plastic code plate ............................................................................................................................................5-90
© BorgWarner Inc.

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 AFTER THE REPA IR OPERA TION IV

TABLE OF CONTENTS

6. AFTER THE REPAIR OPERATION

6.1 Post Repair Checks............................................................................................................................................................6-93
6.2 Repair Validation...............................................................................................................................................................6-93
6.3 Repair Traceability............................................................................................................................................................6-93
6.4 Additional Operations ......................................................................................................................................................6-94
6.5 Measurement Equipment Maintenance.........................................................................................................................6-94
6.6 Storage ...............................................................................................................................................................................6-95

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V A PPEN DIC ES

TABLE OF CONTENTS

7. SCHEDULE
8. INJECTOR EXPLODED VIEW
8.1 Exploded view DFI1.1 to DFI1.4 & DFI2.3.................................................................................................................... 8-101
8.2 Exploded view DFI1.5 / DFI1.5.2 / DFI2.5 / DFI2.5 HPC / DFI2.5.2 / DFI2.5.2 HPC................................................. 8-102
8.3 Exploded view DFI1.20 / DFI2.20 ................................................................................................................................. 8-103
9. REPAIR PROCEDURE SUMMARY
10. TEST BENCH HOLDERS AND FITTING
11. TIGHTENING TORQUES

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 IN TRODUC TION I

INTRODUCTION

1.1 Forward
This DDNX299 manual includes all information on the new injectors fitted to the most recent engines. The new
injectors offer increased performance, particularly with regard to a reduction in emissions, to satisfy the emission
[Link] Euro 3 to Euro 4, BS3 & BS4 and Tier2 to Tier4.
The repair of Common Rail injectors requires the strictest conditions in terms of cleanliness and quality. Follow the
methods and recommendations described in this document and the associated SIN (Technical information DT436 in
Direct Evolution) and use the tools described in the appendix of this manual.
Equipment required :
- A metal-coated bench, used solely for work on the injectors.
- A vice with soft metal jaws.
- Lint-free cloths.
- A "Careclean" type cleaning product.
- The Hydraclamp multi-directional support.
- A plastic tray with numerous compartments to store the injector's internal components.

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- Dismantling and refitting tooling YDT600 (including YDT440 "partial” and YDT640).

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- The YDT645 upgrade kit to manage the change to the 3000 N pre-load.
- The YDT786 upgrade kit to replace the / DFI1.5 mesh filter.
- The YDT647 update kits, for the new DFI2.5HPC / DFI2.5.2HPC injector sockets.
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- The YDT646 update kit, for the new DFI1.20 / DFI2.20 JCB injector sockets.
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- Clean caps and plugs from the dispenser YDT480A / 9109-914.
- Connector plugs from the YDT540 dispenser.
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- A set of master injectors.

- Powderless latex gloves.
- A Hartridge HM1005 / HM1005L ultrasonic washer.
- A Hartridge HM1009 flushing unit.
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- A CR AVM2-PC or CRI-PC test bench with equipment for testing CR injectors and the IRIS test software.
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- Magnification system (30 times) to detect possible dirt.

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- A label printer with the DYMO LabelManager PC program.

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- An EPILOG laser engraving unit or equivalent for engraving the plastic plates.
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Consumables:
- Grease type Mobilith SHC 220.
- ORAPI CT615 type grease.
- LOCTITE 243 or equivalent.
- Ultrasonic wash fluid.
- Rinsing / flushing fluid.
- Label reel.

CAUTION
These master injectors must be tested regularly (at least once per week) to detect any possible deviation from the
test bench.

Note:
It is important that you use a label reel adapted to the engine environment and compatible with the DYMO printer
above. Recommended products: 9001-898 polyester reinforced ribbons and 9001-899 heat shrink.
© BorgWarner Inc.

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I IN TRODUC TION

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Parts for repair:
To ensure the correct operation of the repaired injector, you must replace the faulty components with original
Delphi Technologies parts; the part numbers for these are noted in the parts lists (See Direct Evolution) .
Repair notice:
A "repair notice" must be completed for every injector repaired to include the following information:
- Injector reference.
- Serial number.
- Vehicle mileage.
- Fault codes or symptoms noted during the diagnostic.
- Parts replaced during the repair.
- Summary of test results on the test bench (before and after repair).

1.2 Important Recommendations

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When working on the injector, the cleanliness and safety conditions stipulated in the DDGX200 Common Rail manual

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must be observed.
A full diagnosis of the injector must be carried out before dismantling internal or external parts. You are strongly
recommended to check the injector on the test bench to determine the cause of the fault. (See the appendix for the
test bench supports and fixings)
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Injector components must be reassembled under extremely stringent cleanness conditions (residual dirt can cause
damage to the injectors after reassembly).
- Reused parts must be washed and dried in advance. Before reassembly, such parts must be lubricated with ISO
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4113 fluid.
- During assembly, parts must be stored in a clean area free from metallic, fibrous or other forms of dirt.
- All parts that are to be reused must be visually inspected in terms of their general condition.
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CAUTION
It is vital to use the YDT600 or (YDT440 "partial" + YDT640) + update kit YDT645 removal and refitting tools
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recommended by Delphi Technologies.

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Seals must be replaced systematically each time these parts are dismantled.
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Any parts showing signs of deterioration, corrosion, wear, cracking or deformation must be replaced.

© BorgWarner Inc.

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 IN TRODUC TION I

INTRODUCTION

1.3 Injector Identification

There are several types of Common Rail injectors listed in the evolution table below :
(Consult the DDGX200 general operating principles for details of each variant)

Injector Type DFI 1.1 DFI 1.2 DFI 1.3 DFI 1.4 DFI 1.5 / DFI1.5.2 / DFI1.20 /
DFI 2.3 DFI 2.5 DFI2.5.2 DFI2.20
DFI 2.5HPC DFI2.5.2HP
C
Operating 1400 1600 1600 1800 2000 2000 2000
pressure (bar)
Number of 2 2 3 3 to 5 3 to 5 5 to 7 5 to 7
injections per
cycle

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Emission standard Euro3 Euro3 Euro 4 or Euro 4 / 5 Euro 4 / 5 Euro6 Euro6 or Tier4

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Tier 3 or Tier 4 Stage V Stage V
Test bench 200 200 800 1200 1200 2000 2000
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(millions of cycles)
On vehicle 250000 250000 250000 400000 400000 > 400000 > 400000
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endurance (Km)
Characterization C2I / C3I / C4I (Method 0 to method 4 depending on the application)
External Injector 17 17 17 17 19 19 19
BODY Diameter
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26 (*) 28 (*)
mm
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(*) Body diameter with an HPC configuration (High Pressure Supply with a radial connection).
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Injector Type Technical changes (**)

DFI 1.1
DFI 1.2 Valve seat (“MNS” = machined narrow seat)
DFI 1.3 / DFI 2.3 'MNS' + Improved injector
DFI 1.4 'MNS' + DLC + Valve external return + Injector (needle seat + modified feed/gallery
+ holes)
DFI 1.5 / DFI 2.5 As for DFI 1.4 + CVA = Combined Valve Adapter plate
DFI 2.5HPC
DFI 1.5.2 / DFI 2.5.2 As DFI1.5 + Increased valve return preload spring
DFI 2.5.2 HPC Introduction of the SVA depending on application
Progressive introduction of the “LDF” = Laser Drilled Filter
DFI 1.20 / DFI 2.20 Backleak flow managed under positive pressure between [5 - 6] bar

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Progressive introduction of the LDF

(**) Certain changes in the manufacturing process should be applied during repair as they improve injector
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performance without altering their characteristics.
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CR injectors are identified by a label containing :
• The injector number is composed of 8 numbers with a sequence in “42 000 000” from 2020.
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CAUTION
On the older injectors, it started with the characters EJBR, EJDR or EMBR followed by five figures and a letter.
Then, in 2010, the injectors had a sequence of 8 numbers in “28 000 000”.
The old part numbers which evolved changed part numbers from “28 000 000” then “42 000 000”.
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Consult Direct Evolution for interchangeability.

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• There are two different forms of injector traceability, detailed below :

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1) Internal Delphi Technologies traceability in 11 characters

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• The first 4 digits represent the order number for the injector body for the day.
• 1 letter represents the month of production : A for January, M for December. The letter I is not used.
• 1 letter represents the year of production : U for 2001, V for 2002, A for 2007 etc.
• 2 letters represent the day of production.
• 1 letter represents the production site (see table below).
• 2 numbers represent the number of the test line.

Letter code Country of manufacture Letter code Country of manufacture

A Argentina N China
B Barcelona O India (Uttaranchai)
C UK (Gillingham) P Poland
D Germany Q Ireland
E Spain R Rumania (IASI)
F France (Blois) S Belgium
© BorgWarner Inc.

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INTRODUCTION

Letter code Country of manufacture Letter code Country of manufacture

H Czech Republic U USA
I India (Mannur) V India (Oragadam)
J Japan W France (La Rochelle)
K Korea X Australia
L Italy Y China (Yantai)
M Mexico Z South Africa

2) Daimler traceability in 13 characters

• 2 first numbers represent the year of production.
• 3 following numbers indicate the manufacturing day in 365 days.
• 5 next numbers indicate the injector order number in the day so the first number stays at 0.

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• 1 number represents the production site.

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(8 = France (Blois); 9 = France (La Rochelle))
• 2 numbers represent the number of the test line.
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The rest of the markings indicate :
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• The 'data matrix' used internally in the manufacturing plants. (See DT447 )
• The Engine Manufacturer part number.
• The homologation number for the Engine Manufacturer (future).
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• The C2I / C3I / C4I code is written on a second label or a plastic code plate.

Injectors are also identified by 2 engraved lines :

• 1st line of 4 characters with a letter for the country of manufacture (see previous table) and 3 numbers
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corresponding to the digital part of the injector reference.

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• 2nd line of 8 characters of which 5 numbers correspond to the injector serial number and 3 letters correspond
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to its manufacturing date code.

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Example :
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F087 :
- F -> Manufacturing site = Injector manufactured
at Blois
- 087 = digital part of the injector part number.

48048CBF :
- 48048 = Injector serial number. F087
48048CBF
- CB -> Manufacturing date = March 2008.
- F -> Manufacturing site = Injector manufactured
at Blois
© BorgWarner Inc.

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I IN TRODUC TION

INTRODUCTION

1.4 Internal changes to the injector.

1.4.1 Change Valve CVA => SVA

A change to the CVA valve was introduced to all Delphi Technologies solenoid injectors.
It has improved valve performance by minimizing the lacquer deposition on the slotted portion of the valve.
The valves with a smooth stem were replaced by valves with a slotted stem which are fully interchangeable.
(See DT555 in Direct Evolution)

Chronology CVA valve design

of use
1 Slotted stem
DFI1.5

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2 Stem without
DFI1.5 pack1 slots + partial
DLC
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(DLC = Diamond
iv

Like Carbon)
el d
ph
[D A

3 Stem without
DFI1.5 slots + total DLC
pack1+
© BorgWarner Inc.

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 IN TRODUC TION I

INTRODUCTION

Chronology SVA valve design

of use
4 Principle of the
DFI1.20sv CVA valve
+
Valve guide

4]
The SVA valve allows balancing of the pressure around the guide circumference of the valve and reduces

1 -2p02y
static leaks.

1.4.2 Coil changes

02 11o
/2 29-C
A change to the coil was introduced on all Delphi Technologies solenoid injectors.
Please check the vehicle manufacturer technical documentation in Direct Evolution to identify the coil type.
• There are two coil types :
04 ]n- c[ e

Coil 2 x 28 windings.
- Coil resistance at 20°C must be between 0.155 Ohm and 0.185 Ohm (0.160 Ohm and 0.190 Ohm for
DFI1.5.2 - varies with temperature) .
- Insulation resistance must be greater than 10 Mega Ohms.
VNa

Coil 1 x 56 windings.
iv

- At 20°C the resistance of the coil must be between 0.620 Ohm and 0.650 Ohm ( Varies with
el d
ph

temperature )
[D A

- Insulation resistance must be greater than 10 Mega Ohms.

© BorgWarner Inc.

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I IN TRODUC TION

INTRODUCTION

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

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 DIA GN OS TIC S / C LEA N ING II

DIAGNOSTICS / CLEANING

2.1 Vehicle Symptoms and Rapid Diagnosis

2.1.1 Vehicle symptoms

Symptoms/faults
During the initial diagnostics, you can use the following table to ascertain which function is faulty.

Symptoms observed on the vehicle Possible causes

Dirt in the valve
Corrosion of the valve
Needle stuck due to dirt, corrosion
Dirt in the internal holes

Loss of performance, instability, noise, Edge filter plugged by external dirt

4]
smoke Coil fault, open circuit

1 -2p02y
Electrical connector fault
Injector spring broken
02 11o
Valve spring broken
/2 29-C
Intermittent fault : short circuit / open circuit
Valve stem broken
04 ]n- c[ e

Valve stuck open

Engine over revving
Valve spring broken or damaged (corrosion)
Needle stuck open (corrosion, debris, paint)
VNa

Internal holes partially blocked (debris)

iv

Smoke, uneven idle Leaks at the pressure faces

el d
ph

Wear between the needle / adapter plate

[D A

Uneven electromagnetic force (intermittent fault on the internal

Uneven idle (due to an irregular end of electrical connection)
injection)
Spring fault (corrosion, fatigue)
Injection holes blocked (debris)
Carbon deposit
Loss of power, poor start, risk of stalling
Corrosion
Lacquer
Needle spring broken (corrosion, excessive stress)
Needle spring loose (fatigue due to excessive temperatures or
Poor starting
speeds)
Excessive temperature of the nozzle
© BorgWarner Inc.

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II DIA GNOS TIC S / C LEA N IN G

DIAGNOSTICS / CLEANING

Symptoms observed on the vehicle Possible causes

Injector stuck open
Engine over-revving (due to a fuel leak Debris under the needle seat
via the injector tip between two
consecutive injections) Valve stuck open (debris under the valve seat)
Lacquer

Loss of power, instability, noise due to Edge filter blocked by debris

a poor start of injection Coil : open circuit
Engine stop Coil : short circuit

2.1.2 Diagnostics before dismantling the injector

Before working on the injector, the diagnostics procedure should start with an external inspection.

4]
• Check the condition of the injector:

1 -2p02y
- Excessive scale.
- Tip damaged.
- Sealing washer present.
02 11o
- Condition of the backleak connection.
/2 29-C
- Condition of the M14 thread.
- Condition of the electrical connectors.
04 ]n- c[ e

- Return opening condition (part of back-leak, o ring residue) .

- Body closure ball crimping condition.
• Locate possible leaks:
- Around the nut thread/injector body.
VNa

- Around the backleak connection.

• Liquid level noted:
iv

- Very small quantity (or smell).

el d
ph

- Contacts and external parts completely wet.

[D A

• Fluid type:
- Diesel fuel.
- Oil.
- Other. © BorgWarner Inc.

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 DIA GN OS TIC S / C LEA N ING II

DIAGNOSTICS / CLEANING
2.1.3 Diagnostic harness:
it is possible to carry out injector electrical diagnostics on the vehicle by using the appropriate diagnostic
harnesses. (See DT446 & DT464 in Direct Evolution)

Applications Electrical connector type Appropriate harnesses

FCI - 2 pins
YDT471
APTIV - 2 pins
DFI1.1 to 1.4
DFI2.3 & YDT471

certain DFI1.5 /
YDT471

DFI2.5 / DFI2.5 V
ORPM
(TR/MIN.)

HPC injectors
Ω

USB
IOIO
I

VCI / DIAMAND
CD

DDBX216
AB

4]
Trig

1 -2p02y
DCS - 2 pins YDT479

DFI1.5 / DFI2.5
02 11o I

t YDT479

DFI1.5.2 / DFI2.5.2
/2 29-C
YDT479

HPC
Ω

DFI2.20
ORPM
(TR/MIN.)
04 ]n- c[ e

USB
IOIO
I

VCI / DIAMAND
AB

Trig
CD

DDBX221

AK - 2 pins YDT330 - Cable B

VNa
iv

YDT330B
el d

DFI1.20
ph
[D A

2.1.4 Repair harnesses

If a connector problem is detected on the vehicle wiring loom, it is possible to repair it using the range of
Delphi Technologies repair harnesses listed below (See DT458 in Direct Evolution)
The range of repair harnesses may be used to :
• Avoid replacing a complete harness.
• Make working on the vehicle easier.
• Optimize repair times.
• Guarantee contact quality.
© BorgWarner Inc.

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II DIA GNOS TIC S / C LEA N IN G

DIAGNOSTICS / CLEANING

Repair harness Connector part

Applications Electrical connector type
part number number
DFI1.1 to
DFI1.4
DFI2.3
9001-845)
DFI1.5 / FCI - 2 pins 9001-846)
(Gold contacts)
DFI1.5.2
DFI2.5 /
DFI2.5.2

DFI2.5 / 6407-668)
DFI2.5.2 Reinforced
APTIV - 2 pins 9001-851)

4]
Medium Connector

1 -2p02y
trucks / Vans (Gold contacts)
02 11o
/2 29-C
DFI1.5 /
DFI1.5.2
9001-886)
04 ]n- c[ e

DFI2.5 / DCS - 2 pins 9001-851)

(Gold contacts)
DFI2.5.2
DFI2.20
VNa
iv
el d
ph

9001-925)
[D A

DFI1.20 AK - 2 pins NA
(Contacts silver)

© BorgWarner Inc.

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 DIA GN OS TIC S / C LEA N ING II

DIAGNOSTICS / CLEANING

2.2 Cleaning

2.2.1 Preliminary cleaning

WARNING
It is vital to wear eye protection to avoid injury from scale shards during this operation.
Care must be taken to avoid damaging the nozzle.

For injectors before dismantling

• Extract the sealing washer (copper or steel)
on the nozzle using a pair of universal pliers.
(To check the conformance of the washer,
see note DT412 in Direct Evolution which
summarizes the washers by size and
application)

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e

• Plug the backleak, the injector body M14

thread (see cap and plug dispenser
YDT480 / 9109 - 914 - note DT428 in Direct
VNa

Evolution) and the electrical connector (see

connector plug dispenser YDT540 - note
iv

DT460 in Direct Evolution).

el d
ph

• Using the YDT616 scraper, descale the slot

[D A

between the nozzle capnut and the nozzle.

© BorgWarner Inc.

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II DIA GNOS TIC S / C LEA N IN G

DIAGNOSTICS / CLEANING
• Clean the slot using the YDT621 / YDT622
brushes depending on the nozzle diameter.

CAUTION
The nozzle must not be brushed as this can
hamper its operation.

• Rinse the nut and the injector tip using a

degreaser aerosol.

WARNING
Warning, these products can cause damage to the
hands and eyes. The action takes more or less
time depending on the cleaning product chosen.

• Clean the entire injector using a washing product concentrating on the most at risk areas.

4]
• Dry the injector.

1 -2p02y
CAUTION 02 11o
It is essential that the nozzle is descaled, as the flowmeter is extremely sensitive to contamination.
The injector nozzle must be ultrasonically cleaned before diagnostic testing on the bench.
/2 29-C
For injectors after dismantling
04 ]n- c[ e

• For dismantled injectors, use the thread

cleaners to remove all the dirt stuck to the
NHB threads.
• Tighten the injector using the thread
VNa

cleaner and then undo it.

iv

• If required, finish cleaning the threads by

spraying with a degreaser.
el d
ph

• Dry the injector.

[D A

CAUTION
There are two types of thread cleaners due to the various thread types :
• M15.3 YDT617 (DFI1.2 --> DFI1.4)
• M17 YDT619 for 18.85 mm body (DFI1.5, DFI1.5.2 and DFI2.20)
• M17 YDT649F for 19.1 mm body (DFI1.5, DFI1.5.2 and DFI1.20)
• M17 YDT647D for 19.45 mm body (DFI2.5 and DFI2.5.2)
This operation must be carried out with the injector pointed down to avoid introducing contamination into the
drillings. Dismantle the thread cleaners regularly to clean them.
© BorgWarner Inc.

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 DIA GN OS TIC S / C LEA N ING II

DIAGNOSTICS / CLEANING

4]
1 -2p02y
02 11o
/2 29-C
Plug / Caps range

Several new part numbers have been added to the current range (See DT428 in Direct Evolution) :
04 ]n- c[ e

Part number : Use: Description :

9001-855 Injector backleak for DFI1.5 and DFI1.5.2
VNa
iv
el d
ph
[D A

6407-631 DFI1.20 positive pressure injector backleak.

6407-638 DFI2.5 HPC (*) injector

(Diameter 26 mm - Yellow plug)
© BorgWarner Inc.

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DIAGNOSTICS / CLEANING

Part number : Use: Description :

6407-639 DFI2.5.2 HPC injector

6407-650 17 mm diameter injector centralized backleak for the

DFI2.5.2.

4]
1 -2p02y
(*) "HPC" = High Pressure Connector - Injector with high pressure feed and lateral return.
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

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 DIA GN OS TIC S / C LEA N ING II

DIAGNOSTICS / CLEANING

A B C D E F G H J K

YDT541 YDT542 YDT543 YDT544 YDT545 YDT546 YDT547 YDT548 YDT549 YDT550

L
YDT540 B/D A/B A/B
YDT577

Blanking Connectors Range A M

B/D
A/B
Gamme connecteurs
bouchons
YDT578

„Verschlussstopfensatz“ A/B N

Gamma Tappi di Protezione

B
F YDT579

?
Gama de conectores de B/D
borrado D O
50
Gama Złączek Zaślepiających A/B
A/C YDT580
Ассортимент Заглушек
G/H/J/K/P/R L/M/N P
Gama Złączek Zaślepiających O
B/D

4]
Opções do conectores F YDT581
fornecidos E/F
R

1 -2p02y
L
L
G/H/J/K/P/R YDT582

DDJX001B
02 11o
Connector plugs for Delphi Technologies and other applications
/2 29-C
Connector plug type Connector plug part
Applications
04 ]n- c[ e

(See DT460 in Direct Evolution) number

DFI1.1 to 1.4
DFI2.3
FCI - 2 pins
VNa

certain DFI1.5 /
DFI2.5 injectors
iv

YDT545
el d
ph

DFI2.5 / DFI2.5.2
[D A

Medium trucks / APTIV - 2 pins

Vans

DFI1.5 / DFI2.5
DFI1.5.2 & DCS - 2 pins YDT546
DFI2.5.2)
© BorgWarner Inc.

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II DIA GNOS TIC S / C LEA N IN G

DIAGNOSTICS / CLEANING

Connector plug type Connector plug part

Applications
(See DT460 in Direct Evolution) number

DFI1.20 AK - 2 pins YDT542

2.2.2 Ultrasonic cleaning

4]
• Protect the electrical connector using the

1 -2p02y
correct plug from the YDT540 dispenser.
• Immerse the injector (with the internal
02 11o
components if the injector has been
dismantled) in the Hartridge HM1005 /
/2 29-C
HM1005L ultrasonic tank.
• Run the ultrasonic cleaning cycle as long as
04 ]n- c[ e

is necessary (the time depends on the

degree of contamination).
• Dry the injector.
VNa
iv
el d
ph

WARNING
[D A

Gloves must be worn during the entire operation to protect the skin.
Use the metal basket for internal components to avoid dropping them.
Replace the liquid at the recommended intervals to ensure effective cleaning.
© BorgWarner Inc.

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 DIA GN OS TIC S / C LEA N ING II

DIAGNOSTICS / CLEANING
2.2.3 Rinse cleaning

• Use the Hartridge HM1009 rinsing tank with

the Hartridge YDT625 flushing kit for the
rinsing operation.
• Remove the injector capnut and all the
internal components (nozzle, needle spring,
adapter plate, valve body, valve spring and
calibration pin).
• Protect the electrical connector with the
correct plug from the YDT540 dispenser
(depending on the injector model).

4]
1 -2p02y
• Connect the YDT624 manifold to the supply
tube and screw the injectors to the manifold.
- for bodies with the M17 thread.
02 11o
- For bodies with M15.3 threads, use the
/2 29-C
YDT626 adapter rings and the YDT627
plugs.
• Close the transparent cover and run the
04 ]n- c[ e

rinsing operation with the pressure set to

2.5 bar.
• Dry the injector body.
VNa
iv
el d
ph

Filter variants in the High Pressure M14 connection :

[D A

Edge filter : Mesh filter : LDF :

("Edge filter") ("Mesh filter") (LDF = "Laser Drill filter")

CAUTION
This operation only applies to dismantled injectors.
When cleaning injectors with the HM1009 tank, use the HM1021 update. For further information, refer to the
Hartridge technical bulletin.
The transparent cover must be used.
© BorgWarner Inc.

The red valve must not be switched during this operation.

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II DIA GNOS TIC S / C LEA N IN G

DIAGNOSTICS / CLEANING
2.2.4 Application

A) To carry out a diagnostic procedure

Clean the injector nozzle in the ultrasound tank before installation on the diagnostic test bench.
B) To carry out repairs
Dismantle the injector and scrap the parts that cannot be reused (needle, valve, capnut).
Clean the injector body (with the electrical connector plugged) in the ultrasound tank and rinse.
Clean the internal parts that can be reused in the special ultrasound tank.
Reassemble the injector in a filtered laminar flow cabinet.

2.3 Test Bench Diagnostics

2.3.1 Electrical tests.

4]
Electrical tests must be run on a test bench using the correct control cables.

1 -2p02y
CAUTION
There are 3 types of cables to manage all the injector types :
•
02 11o
N°1 : For DFI1.1 to 1.4, DFI2.3 and certain DFI1.5 / DFI2.5 injectors.
• N°2 : For the rest of the injectors DFI1.5 / DFI2.5 / DFI1.5.2 / DFI2.5.2 / DFI2.20
/2 29-C
• N°3 : For the DFI1.20 injectors.
04 ]n- c[ e

This test is carried out in two stages :

a. First check the condition of the coil.
Install the injector on the test bench (See the appendix for the mounting spacers and the test bench
torque values) and measure the coil resistance.
VNa

There are two coil types :

iv

Coil 2 x 28 windings.
el d

Coil resistance at 20°C must be between 0.155 Ohm and 0.185 Ohm (0.160 Ohm and 0.190 Ohm for
ph

DFI1.5.2 - varies with temperature) .

[D A

Insulation resistance must be greater than 10 Mega Ohms.

Coil 1 x 56 windings.
At 20°C the resistance of the coil must be between 0.620 Ohm and 0.650 Ohm ( Varies with
temperature )
Insulation resistance must be greater than 10 Mega Ohms.
b. Second check the mobility of the valve.
Start the valve test. This is an automatic test that carries out a predetermined number of valve stroke
cycles.
© BorgWarner Inc.

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 DIA GN OS TIC S / C LEA N ING II

DIAGNOSTICS / CLEANING
If the coil resistance lies within the tolerances
and movements of the valve are audible, the
electrical part of the injector is operational.
Caution :
The electrical test assumes that the connections,
insulation and electrical continuities in the bench
control circuit are correct.
The YDT720 kit also assists these tests (See
DDNX405 and DT654 user manuals).
(Resistance, Inductance, Insulation and activation
of the valve)
If the diagnostics show a fault on the coil, scrap
the injector.

4]
CAUTION
For all bench tests, you must first ensure that the ISO 4113 test fluid and the hydraulic circuits (all HP hoses

1 -2p02y
and the rail) are perfectly clean. We strongly recommend cleaning the circuits to ensure that all dirt is
removed (metallic, organic or other). In particular, ensure that the 2 µm filter is replaced regularly. Failure to
02 11o
observe these recommendations can damage the injectors to be tested.
/2 29-C
Before fitting any injector to the test bench, it is vital to carry out the all the recommended cleaning steps
described in the previous section.
04 ]n- c[ e

2.3.2 Static leakage test

At this stage you must ensure that the injector

VNa

does not leak in static mode:

iv
el d
ph
[D A

1. Fit the injector support spacer to the bench (The part number is listed in the injector test plan). This
part helps detect and recover leaks from the nozzle.
2. Install the injector on the test bench once all cleanness precautions have been taken.
3. Tighten the HP pipe to a torque of 25 Nm on the rail side, followed by the injector side.
4. Connect the injector backleak directly to the flowmeter using the special connectors in the YDT586A kit.
5. Start the static leakage test via IRIS.
© BorgWarner Inc.

6. Check for static leaks from the nozzle (injected flow) and from the groove between the capnut and the
nozzle holder body.
7. Measure the static leak flow (backleak).

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DIAGNOSTICS / CLEANING
- Static backleak above the maximum limit (fixed in IRIS) or appearance of leaks around the nozzle
or around the nut/nozzle holder body slot, the injector is leaking. The unit must be dismantled to
diagnose a fault on internal parts.
- Static backleak below the maximum limit (fixed in IRIS) or no leaks around the nozzle or around the
slot, the injector is leak-free. In this instance, perform a dynamic leakage test.

CAUTION
In order to preserve the HP pipe, do not tighten to a torque exceeding the stated value.

2.3.3 Dynamic leakage test

The dynamic leakage test consists of measuring the backleak from the injector under specific operating
conditions. The unit will be controlled so as to reproduce injections pre-calibrated in IRIS. To ensure this,
remove the previously used spacer and replace it with a spacer without a lateral hole. Before starting the flow
measurements, the following conditions must be met:
- Generate a minimum temperature of 40°C for the test fluid (ISO4113).

4]
- Cleaning and temperature adjustment of the injector.

1 -2p02y
- Start the dynamic leakage test via IRIS.
- Measure the average backleak, if the flow exceeds the maximum limit (fixed in the IRIS test schedule),
02 11o
the injector is faulty (valve wear).
/2 29-C
2.3.4 Fuel deliveries and opening delays
If the injector tested is leak-free, measure the injected flows and opening delays at the pressures pre-
04 ]n- c[ e

calibrated in the test schedule.

Note:
On the CRiPC 4 line bench or the CRi300 it is possible to test 4 injectors at a time. On the AVM2PC bench, only
VNa

one line can be run at a time.

iv

During this stage, simply launch the "Diagnostics" program on IRIS. For each rail pressure and for each pulse,
el d
ph

the injected flow and the opening time will be measured in mm 3/shot and in µs respectively. The results
[D A

obtained are compared to the target data for the injector in question.
If the curves for flow and opening delay lie within the tolerances, remove and cap the injector. You must
observe the cleanness regulations recommended by Delphi Technologies throughout the entire operation.
If the characteristics measured for this injector lie outside of the tolerances, remove the injector from the
test bench, then dismantle the injector and replace the faulty parts; be sure to observe the relevant cleanness
and safety guidelines.
© BorgWarner Inc.

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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING

3.1 Introduction

3.1.1 Injector repair - when to apply (other than special agreements)

Repairs do not apply in the following cases:
- The vehicle's mileage is less than 80,000 km.
- The injector is under warranty.

3.1.2 Faults and replacing parts

The table below summarizes the most common faults detected on the test bench and the parts to replace in
each case.

Parts to replace
Needl
Valve/
Mesh

4]
e/ CVA /
Fault Injector Adapte seat Valve Calibrati
filter

1 -2p02y
Capnut body SVA /
type spring r plate assembl spring on pin
assem (DFI1.5) valve
y
bly
02 11o
Resistanc
Discard the injector
/2 29-C
e
No If the resistance is ok, see below :
04 ]n- c[ e

vibration
of the X X X X X
valve
Static
VNa

leak
X X X
iv

(backleak
el d

)
ph
[D A

Static
leak X X X
(nozzle)
Dynamic
X X X X X X X
leak
Pilot fuel X X X X X X X X X
Main fuel X X X X X X X X X
Opening
X X X X X
delay

This table is given solely for reference purposes, as it is simply impossible to replicate all of the part
replacement options according to the different types of injector faults. In fact:
- Wear on a part can result in different fault modes on the injector.
- A given fault on the injector can be caused by a combination of several faulty parts.
In order to improve repair reliability, it is possible to systematically replace all worn parts every time the
© BorgWarner Inc.

injector is dismantled (valve, valve body, injector assembly, springs).

Note:

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III DIS M A N TLING / REA S S EM BLY

DISMANTLING
In the case of the DFI1.20, a leak at the nut indicates a reduction in section or a blockage in the injector
backleak connection.

3.1.3 Description of parts

Refer to appendix I of this document.

3.2 Tools

In order to make handling easier and protect the parts to be dismantled, Delphi Technologies has developed several
tool kits for solenoid injector repair.
The YDT600 kit including the ( YDT440 "partial" + YDT640 and YDT645 (update kit phase 2) must be used when
working on injectors.
This update kit allows the pre-load (3000 N) to be applied to the internal components during reassembly.

4]
Note:
2 possible assemblies :

1 -2p02y
• either YDT440 + YDT640 + YDT645.
• or YDT600 + YDT645 .
02 11o
The assembly with the old YDT645 is shown on the notice supplied.
/2 29-C
CAUTION
To improve injector performance (less distortion on the valve seat), the preload has been increased to 3000 N.
04 ]n- c[ e

(rather than the original 500 N.) to better seat the internal components of all types of Delphi Technologies solenoid
injectors. A reinforced bar is included in the YDT645 kit to withstand the extra effort.
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa

YDT600 upgrade with the YDT645 kit

iv
el d
ph
[D A
© BorgWarner Inc.

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III DIS M A N TLING / REA S S EM BLY

DISMANTLING

Complete Kit part Part Name Operation Illustration

kit part number number
number
YDT600 YDT440 YDT437 Right hand To hold and rotate the
bearing fixed injector during repair
+ movable operations.
left hand
bearing

YDT438 Nut cutter To score the NHB capnut

to release the internal

4]
stresses.

1 -2p02y
(YDT442 : Roller and
knurl kit)
02 11o
/2 29-C
04 ]n- c[ e

YDT441 Cutter label To remove the NHB label.

VNa
iv
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[D A

YDT443 Open snap To extract the snap ring

ring pliers inside the gland nut
(Ford Puma).

YDT444 Snap ring To assemble the snap

fitting sleeve ring on the outer NHB
gland nut (Ford Puma).
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DISMANTLING

Complete Kit part Part Name Operation Illustration

kit part number number
number
YDT600 YDT440 YDT445 Metal cap To protect the nose of
the NHB when fitting the
external gland nut.

YDT446 Nut fitting To fit the outer NHB

sleeve gland nut (Ford Puma).

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e

YDT447 Injector To hold the NHB when

support fitting the gland nut.
(width = 15 mm)
(height = 15 mm)
VNa
iv
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[D A

YDT640 YDT601 Main repair To hold the injector in

(phase 1 support position during repairs.
update
kit)
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DISMANTLING

Complete Kit part Part Name Operation Illustration

kit part number number
number
YDT600 YDT640 YDT611 Drive socket To drive the injector in
(phase 1 (injectors rotation for
update with radial dismantling /
kit) feed other reassembly operations.
than DFI1.5
type
Peugeot
Citroen &
Ford)
YDT612 M14 metal To protect the NHB HP
plug inlet threads during

4]
repair operations.

1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e

YDT613 Injector To hold radial feed NHBs

adapter in position (used with
YDT611).
VNa
iv
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[D A

YDT614 Code plate To extract the injector

extractor code plate.
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DISMANTLING

Complete Kit part Part Name Operation Illustration

kit part number number
number
YDT600 YDT640 YDT615 Drive socket To drive the injector in
(phase 1 rotation for
update dismantling /
kit) reassembly operations.

YDT616 Scraper For cleaning out the

scale between the

4]
nozzle and the capnut

1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e

YDT617 M15.3 thread For cleaning the M15.3

cleaner threads on injector
bodies with a 16.85 mm
diameter (DFI1.2 to
VNa

DFI1.4)
iv
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[D A

YDT619 M17 thread For cleaning the M17

cleaner threads on injector
bodies with an 18.85 mm
diameter (DFI1.5)

YDT621 Brush For cleaning out the

scale between the 7 mm
diameter nozzle and the
capnut
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DISMANTLING

Complete Kit part Part Name Operation Illustration

kit part number number
number
YDT600 YDT640 YDT622 Brush For cleaning out the
(phase 1 scale between the 9 mm
update diameter nozzle and the
kit) capnut

YDT632 Label To hold the code plate in

support position during laser

4]
(HMC marking.

1 -2p02y
Applications)
02 11o
/2 29-C
04 ]n- c[ e

YDT633 Label To hold the code plate in

support position during laser
(Peugeot marking.
Citroen &
VNa

Ford DW10C
iv

Euro5
applications)
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[D A

YDT634 Label To hold the code plate in

support position during laser
(Peugeot marking.
Citroen
DW10B
Euro4 & 5
applications)

YDT636 Code plate To hold the code plate in

support position during laser
(GMDAT Z20 marking.
& Z22 Euro5
applications)
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DISMANTLING

Complete Kit part Part Name Operation Illustration

kit part number number
number
YDT600 YDT640 YDT637 Reel To retain the film roll
(phase 1 when printing labels.
update
kit)

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
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[D A
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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT645 YDT638 (A Reinforced bar To reinforce the main support to
(phase 2 +B) + compression apply the compression effort
update kit) bolt during reassembly.

YDT639 (A Bar + spacer To fix and lock the movable

+B) saddle.

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e

YDT641A DFI1.5 drive To rotate the DFI1.5 injector

socket (type Peugeot Citroen & Ford
DW10F Euro6).
VNa
iv
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[D A

YDT641B DFI1.5 For centering the head of the

centering ring DFI1.5 (type Peugeot Citroen &
Ford DW10F Euro6) on the NHB
axis.

YDT641C DFI1.5.2 guide To hold the NHB in the drive

ring socket.
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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT645 YDT642 Code plate To hold the code plate in
(phase 2 support position during laser marking.
update kit)

YDT643 Reinforced To drive the injector in rotation

drive socket for dismantling / reassembly

4]
(injectors with operations.

1 -2p02y
axial feed)
02 11o
/2 29-C
04 ]n- c[ e

YDT644 Indexing mark To note the angle during

clamp assembly.
VNa
iv
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[D A
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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT647 YDT647A DFI2.5 HPC To drive the injector in rotation
reinforced for dismantling / reassembly
drive socket operations.
(Body
diameter 26
mm)

YDT647B DFI2.5 HPC To hold the NHB in the drive

guide ring socket.

4]
(Body

1 -2p02y
diameter 26
mm) 02 11o
/2 29-C
04 ]n- c[ e

YDT647C DFI2.5 HPC O To avoid damage when fitting

ring mounting the O ring to the body
ring
(Body
VNa

diameter 26
iv

mm)
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[D A

YDT647D M17 thread For cleaning the M17 threads on

cleaner injector bodies with 19.45 mm
diameters or greater (DFI2.5 &
DFI2.5.2)
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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT646 YDT649A DFI1.20 To drive the injector in rotation
reinforced for dismantling / reassembly
drive socket operations.
See DT678 if requiring return or
modification of the drive socket
you already have

YDT649B DFI1.20 To hold the NHB in the drive

holding ring socket.

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e

YDT649C C3I/C4I label To hold the label during laser

support engraving
(Variant VW group - DFI1.20)
VNa
iv
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[D A

YDT649D DFI1.20 outlet To unblock the internal outlet

cleaning stem drilling to be unblocked
(Always store the tool with the
protective plug)

YDT649E DFI2.20 O ring To avoid damage when fitting

mounting cone the O ring (Only works when the
capnut and nozzle have been
removed).
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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT646 YDT649F M17 thread For cleaning the M17 threads on
cleaner injector bodies with a 19.1 mm
diameter (DFI1.5, DFI1.5.2,
DFI1.20)

Complete Part Name Operation Illustration

4]
kit part number

1 -2p02y
number
YDT646 YDT787 Extraction of Allows extraction of the "AK"
the "AK" connector from the DFI1.20
(A/B/C/D/
02 11o
E/F) DFI1.20 injector
/2 29-C
connector
04 ]n- c[ e
VNa

YDT787 Fitting the Allows fitting of a new "AK"

iv

(A/C/D/E/ "AK" DFI1.20 connector module to the DFI1.20

F/H) connector injector
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[D A

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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT646 YDT717A DFI2.20 To drive the injector in rotation
reinforced for dismantling / reassembly
drive socket operations.

YDT717B DFI2.20 To hold the NHB in the drive

holding ring socket.

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e

YDT717C C3I/C4I label To hold the label during laser

support engraving
(Variant JCB - DFI2.20)
VNa
iv
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[D A

Complete Part Name Operation Illustration

kit part number
number
YDT798 YDT798 DFI1.5.2 / To drive the NHB in rotation for
DFI2.5.2 dismantling / reassembly
reinforced operations (JAC Application) and
drive socket injectors with nipple.
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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT799 YDT799A DFI2.5.2 To drive the injector in rotation
reinforced for dismantling / reassembly
drive socket operations.
(Application YUNNEI F40 / F45 /
D40 / D45 & Yuchai 4S)

YDT799B DFI2.5.2 To hold the NHB in the drive

centering socket.

4]
socket

1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
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[D A

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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT786 YDT786A DFI1.5 dummy To supply the injector body with
nozzle high pressure during mesh filter
extraction.

YDT786B DFI1.5 dummy Allows component assembly

(YDT786B1 nozzle nut during mesh filter extraction.

4]
from

1 -2p02y
03/2016)
02 11o
/2 29-C
04 ]n- c[ e

YDT786D O-ring pack Seal between the YDT786A

dummy nozzle and the CVA.
VNa
iv
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[D A

YDT786E Mesh filter To collect the mesh filter during

recovery hydraulic extraction.
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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT786 YDT786F Teflon packing To pack the Teflon in the HP pipe.
tool

YDT786 Concentric Allows the mesh filter to be

(G/H/I/J) axial version in fitted in the axial configuration

4]
the M14 in the M14.

1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e

YDT786 Angled radial Allows the mesh filter to be

(G/K/L/M/ version in the fitted in the angled radial
N/O/P) M14 configuration in the M14.
VNa
iv
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[D A

YDT786Q Injector Used to hold the injector in the

support vice
(width = 12.1 mm)
(height = 17 mm)

YDT786R Injector Used to hold the injector in the

support vice
(width = 13.1 mm)
(height = 13.7 mm)
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DISMANTLING
LDF filter Extraction and Insertion Tool
Complete Part Name Operation Illustration
kit part number
number
YDT786 YDT786F Teflon packing To pack the Teflon in the HP pipe.
tool

YDT786 Concentric Allows the mesh filter to be

4]
(G/H/I/J) axial version in fitted in the axial configuration

1 -2p02y
the M14 in the M14.
02 11o
/2 29-C
04 ]n- c[ e

YDT786 Angled radial Allows the mesh filter to be

(G/K/L/M/ version in the fitted in the angled radial
N/O/P) M14 configuration in the M14.
VNa
iv
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[D A

YDT786Q Injector Used to hold the injector in the

support vice
(width = 12.1 mm)
(height = 17 mm)
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DISMANTLING

Complete Part Name Operation Illustration

kit part number
number
YDT786 YDT786R Injector Used to hold the injector in the
support vice
(width = 13.1 mm)
(height = 13.7 mm)

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
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[D A

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DISMANTLING

3.3 Preparation for dismantling

CAUTION
The injector must not be dismantled in the same area as that reserved for assembly.
You must wear powderless disposable latex gloves when working on the injector.

At this stage, the injector is assumed to be clean externally (descaling and cleaning).
- Remove the sealing washer (copper or steel)
using a pair of universal pliers.
- For PSA injectors with the DV4 or DW10B
engines: extract the external snap ring using the
YDT443 snap ring pliers.

4]
1 -2p02y
02 11o
/2 29-C
CAUTION
04 ]n- c[ e

The injector clamp must be removed to gain access to the C2I / C3I / C4I plastic code plate.

3.4 Repair Equipment upgrade

VNa
iv

Update the repair equipment with the YDT645 update kit by following the instructions supplied.
The main updates are as follows:
el d
ph

• Reinforced support YDT601 + YDT638>, for the new 3000 N preload for all injectors.
[D A

• Reinforced socket YDT643, to drive axial feed injectors.

• Centering ring YDT641B + drive socket YDT641A + guide ring YDT641C, to centre and drive [Link].

3.5 Fitting the injector on the support

Install the injector on the YDT601 + YDT638 main

holder and hold it in position.
In order to compensate for different injector lengths,
it is possible to move the saddle in the support slider.
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DISMANTLING

3.6 Identification support

3.6.1 Adhesive label

• Choose the rotation drive socket (YDT615

or YDT643 or reinforced YDT798) depending
on injector type.
• Orient the socket towards the flat surfaces
of the injector and couple them.
• Use the YDT441 tool to remove the label
from the injector. See figure below.

4]
1 -2p02y
Injector types Injectors with axial feed Injectors with axial feed Injectors with axial feed
02 11o
(with backleak nipple) (without backleak (with backleak nipple
/2 29-C
nipple) plug)
Part number YDT615 YDT643 YDT798
04 ]n- c[ e

Illustration
VNa
iv
el d
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[D A

CAUTION
After removing the label, the application area
must be thoroughly cleaned. Remove all traces of
adhesive or other material. The quality of the
surface determines the effectiveness of the
adhesive on the new label.
If the original label is undamaged after
degreasing, a new label may be directly applied
over the original.
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DISMANTLING
3.6.2 Plastic code plate

WARNING
Eye protection must be worn to avoid injury if the
code plate splits.

4]
1 -2p02y
Certain injectors fitted with a plastic C3I / C4I
code plate must have the plate removed and
replaced with a new blank plate on which the new
02 11o
code has been engraved after repair and test.
/2 29-C
Use the YDT614 plate extractor to remove the
plate and remove the pin with a pair of pliers.
04 ]n- c[ e
VNa
iv
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[D A

For the DFI1.20, the label is fixed on the electrical

connector.
The label can be removed by lifting the peripheral
tabs.
The coil joint is sealed with an O ring.
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DISMANTLING

3.7 External Parts

3.7.1 External gland nut - Ford Puma

To dismantle this injector, you must first remove

the external nut (Glandnut). Fit the long socket to
the YDT601 main fixture. Insert the injector
connecting the gland nut to the long socket
YDT437. Fasten the tube cutter YDT438 on the
main fixture so that the knurl is positioned as
shown in the figure opposite (in the middle of the
indicated area).

4]
1 -2p02y
02 11o
Cut the nut progressively : for two turns of the
/2 29-C
crank, rotate the tightening knurl on the tube
cutter a quarter turn.
Extract the nut and the internal spring clip using
04 ]n- c[ e

the YDT443 pliers.

CAUTION
Failure to observe these recommendations can
VNa

damage the knurl and the rollers. If the cutting

wheel is worn, replace it with part number
iv

YDT442. (See DT437 in Direct Evolution).

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[D A

3.7.2 External gland nut - Yuchai 4W

This injector uses a gland nut to clamp it to the

cylinder head.
Replacement is only carried out if it is damaged:
• Hexagon condition.
• Thread condition.
The test solution is with the nut in place.
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DISMANTLING

WARNING
Eye protection must be worn to avoid injury if the
gland nut splits.

If the repair of the injector requires the Glandnut

4]
to be removed, use a hexagonal 26 mm nut splitter.

1 -2p02y
Position the nut splitter on the hexagonal portion
of the injector. 02 11o
Centre the nut splitter on the centre of a hexagon
flat.
/2 29-C
04 ]n- c[ e
VNa
iv

Tighten the nut splitter until the gland nut splits.

el d
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Loosen the nut splitter and repeat the operation

[D A

at 180°.
The gland nut is in 2 pieces.
Check the condition of the clamp spring ring on
the injector.
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DISMANTLING
3.7.3 Injector capnut

Before unscrewing the nozzle cap, you must first

release the nut/nozzle holder body stresses to
prevent the internal pins shearing. To do this,
make a groove in the nut using the YDT438 tube 25 - 30 mm
cutter. The groove must be positioned 25 to 30
mm from the edge of the nut and the depth must
be less than 0.5 mm
(If the roller or knurls are worn, use the YDT442 kit)

CAUTION
Do not cut the groove on the capnut thread area
as the stress will not be relieved.
Do not cut the nut as this can hamper dismantling.

4]
To loosen the nut, the correct socket for each injector type must be used.

1 -2p02y
Type of Injectors with
02 11o Injectors with Injectors with Injectors DFI1.5 Injectors with
injector axial feed (with axial feed radial feed (Type Peugeot axial feed (with
backleak nipple) (without Citroen & Ford backleak nipple)
/2 29-C
backleak nipple) DW10F Euro6)
Part YDT615 YDT643 YDT611 + YDT641 (A-B-C) YDT798
04 ]n- c[ e

number YDT612 +
YDT613
Illustrati
VNa

on
iv
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[D A

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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING
Injectors with axial feed
• Use the reinforced socket YDT643 to rotate
the injector to score the surface with the
YDT438 tube cutter.

4]
• Install the YDT437 short socket on the

1 -2p02y
injector capnut to limit the rotation of the
latter. 02 11o
• Partially unscrew the nozzle cap.
• Remove the injector from the main fixture.
/2 29-C
04 ]n- c[ e
VNa
iv
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Injectors with radial feed

[D A

• Remove the code plate and extract the pin.

• Use the YDT611 drive socket to rotate the
injector.
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• Tighten the YDT612 thread protection plug
on the injector feed inlet and position it on
the support using the YDT613 adapter as
shown opposite.

• Cut the groove then fit the YDT437 short

4]
socket onto the injector capnut.

1 -2p02y
• Partially unscrew the nozzle cap.
• Remove the injector from the main fixture.
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv

Injectors DFI1.5 (type Peugeot Citroen & Ford DW10F) with offset radial feed
el d
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• Remove the code plate and extract the pin.

[D A

• Use the YDT641 (A-B-C) drive kit to rotate

the injector.
• First fit the centering ring YDT641B on the
injector.
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• Put the injector assembly in the YDT641A
drive socket (part number towards you) and
couple the latter to the YDT641C guide ring
as shown opposite.

• Cut the groove then fit the YDT437 short

4]
socket onto the injector capnut.

1 -2p02y
• Partially unscrew the nozzle cap.
• Remove the injector from the main fixture.
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv

DFI2.5 HPC injectors (type TATA 5L & 26mm body diameter) with HPC feed and lateral return
el d

• Remove the C2I/C3I/C4I label

ph

• Use the YDT647 (A-B-C) drive kit to rotate

[D A

the injector.
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Put the injector assembly in the YDT647A drive
socket (part number towards you)

Finish by connecting the latter to the YDT647B

4]
guide ring.

1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv

• Cut the groove then fit the YDT437 short

el d
ph

socket onto the injector capnut.

[D A

• Partially unscrew the nozzle cap.

• Remove the injector from the main fixture.

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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING
DFI1.20 injectors (type VW group Euro6) with positive pressure backleak
• Use the YDT649 (A-B-C) drive kit to rotate
the injector.
• First fit the retaining ring to the injector.

4]
Put the injector assembly in the YDT649A drive

1 -2p02y
socket (part number towards you)
See DT678 if requiring return or modification of
02 11o
the drive socket you already have
/2 29-C
04 ]n- c[ e
VNa
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Finish by connecting the latter to the YDT649B

[D A

guide ring.
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III DIS M A N TLING / REA S S EM BLY

DISMANTLING
• Cut the groove then fit the YDT437 short
socket onto the injector capnut.
• Partially unscrew the nozzle cap.
(Caution : use the appropriate socket - 6
flats YDT437).
• Remove the injector from the main fixture.

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
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[D A

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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING
DFI2.5.2 injectors (type Yunnei "F40 / F45") with lateral feed via a special forging
Caution : The size of the forging with the High
Pressure feed does not allow rotation of the body
in the fitting.

4]
For this type of injector, the capnut must be

1 -2p02y
grooved off the support by turning the YDT438
tool around the body as for a tube cutter.
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
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• Remove the injector O ring.

[D A

• Refit the injector into the support.

• Fit the YDT437 short socket onto the
injector capnut.
• Partially unscrew the nozzle cap.
• Remove the injector from the main fixture.
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DISMANTLING

3.8 Internal Parts

• Fully unscrew the nut by hand.

CAUTION
Take care not to drop any internal parts (needle,
springs, spacer, valve, etc.)

As soon as the injector is dismantled, separate

the internal parts in a dismantling tray.

4]
1 -2p02y
• Remove the valve spring and the calibration pin
located in the bottom of the nozzle holder body
housing.
02 11o
/2 29-C
04 ]n- c[ e
VNa
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[D A

3.9 Edge / Mesh filter - DFI1.5

DFI1.5 injectors use two types of HP inlet filters:

• Edge filter.
• Mesh filter.
Edge filter.
This filter is factory press fitted into the M14 HP
connector.
There are two types of design:
• Euro 3 to Euro 5 with a spiral cylinder where the
diameter remains the same.
• A converging slot from Euro 6.
Only reverse flushing is possible to remove
contamination from this filter.
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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING
Mesh filter.
This filter is factory press fitted into the M14 HP
connector.
The filter is made up of multiple layers of mesh grids.
When an injector is repaired, the filter must be replaced.

When inverted flushing is applied, it is not possible to

4]
remove the contaminants trapped in the mesh. This

1 -2p02y
will lead to excessive load losses in injector behavior.
This may lead to to mesh particles breaking away and
contaminating the injector (CVA, nozzle...)
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv

Mesh filter extraction requires a test bench capable of generating 500 bar minimum (IFT70 for example).
el d
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CAUTION
[D A

Safety procedures must be applied when using this hydraulic extraction method (safety goggles and gloves,
application of all the safety tools indicated and closure of all safety covers)

The principle of the operation is to use a teflon plug to

push the mesh filter out using hydraulic pressure.
Unroll 10 cm from a roll of 0.2 mm minimum thickness
teflon.
Reroll the ribbon in 2x5 cm then twist it until it has the
same diameter as the injector drilling.
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III DIS M A N TLING / REA S S EM BLY

DISMANTLING
Recut the ends - Final length around 4 cm.
push the teflon plug into the injector body.

Push the teflon roll into the drilling using the YDT786F

4]
tool.

1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
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Block the CVA return with the teflon.

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[D A

Note:
In order to carry out this operation for each repair,
retain this blocked valve for the future injectors to be
repaired.
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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING
Check the <YDT786C seal on the YDT786A injector
dummy nozzle.
A pack of 4 YDT786D seals is supplied with the tool.
O-Ring characteristics :
• Internal diameter = 5.7 mm.
• Ring diameter = 1.2 mm.
• Material = FPM70 or equivalent.
(Resistance to hydrocarbons)

Pre-assemble the plugged CVA with the YDT786A tool

4]
and fit with the special nut YDT786B1.

1 -2p02y
Caution :
Check the orientation of the CVA as it is possible to
invert it.
02 11o
(Absence of pressure rise and the flow passes directly
/2 29-C
via the injector backleak)
The valve must face the return spring.
04 ]n- c[ e

Remarks : From Mars 2016, the YDT786B nut has been

replaced with the YDT786B1.
(If necessary, contact the Delphi Technologies
Technical Service)
VNa
iv

Fix the injector body in the vice with the YDT786Q or

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YDT786R supports.
[D A

Finalise the tightening of the special nut YDT786B.

Tighten to 20 Nm while applying a counter-torque on
the dummy nozzle. (13 mm & 18 mm flat spanners)
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III DIS M A N TLING / REA S S EM BLY

DISMANTLING
Tighten the mesh filter recovery unit YDT786E.

Position the injector on the test machine and orient

4]
the HP connector as appropriate.

1 -2p02y
Connect two YDT273 containers to limit liquid
splashing during the extraction:
• On the injector backleak.
02 11o
• On the collector end.
/2 29-C
Select a Delphi Technologies injector in the menu.
Connect an additional injector to the control harness
04 ]n- c[ e

to fool the machine.

VNa
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[D A

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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING
Close the protection housing and set the presser to a
minimum of 500 bar.

Activate the pressure supply for the injector to trigger

4]
the hydraulic extraction of the mesh filter.

1 -2p02y
The mesh filter will be ejected from its housing due to
the pressure and the teflon roll which will exert a
piston force on the mesh filter surface.
02 11o
Reduce the test machine pressure.
/2 29-C
04 ]n- c[ e
VNa
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The mesh filter will be pushed out by the teflon piston

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and projected into the YDT786E connector.

[D A

Recycle the mesh filter and the teflon plug.

Vital: Rinse the injector body in both directions using 2 µm filtered ISO fluid to remove all particles and teflon
residues in the HP drilling.
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III DIS M A N TLING / REA S S EM BLY

DISMANTLING
To the M14 :
Use the kit YDT625 and connector plugs YDT545 or
YDT546.
• Connect the YDT624 manifold to the supply tube
and screw the injectors to the manifold.
• Close the transparent cover and run the rinsing
operation with the pressure set to 2.5 bar.
• Dry the injector body.

M14 to the lower part :

4]
• Use the YDT786E adapter to supply the M14 with

1 -2p02y
ISO4113 fluid.
• Close the transparent cover and run the rinsing
02 11o
operation with the pressure set to 2.5 bar.
• Dry the injector body.
/2 29-C
04 ]n- c[ e
VNa
iv

3.10 Connector DFI1.20 / DFI2.20

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[D A

CAUTION
It is vital to wear safety glasses. The cleaning stem
must be covered with its protective plug.
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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING
DFI1.20 / DFI2.20 injectors have a positive pressure[5 -
6] bar backleak.
The internal diameter of the connector is 0.5 mm and
it is vital to ensure that there is no obstruction by
contaminants.
Push the YDT649D cleaning tool into the connector
and apply a reverse flush flow to the injector.

Use the YDT754 and a 2 µm filtered test fluid source to

4]
flush the connector.

1 -2p02y
Check that the flow reaches the other end of the injector.
The flush flow will drain via the injector body.
02 11o
Use a YDT542 or YDT546 connector plug to protect the
contacts and the injector coil during this operation.
/2 29-C
04 ]n- c[ e
VNa
iv

Once the flushing has been completed, plug the

el d
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injector backleak with a new 6407-631 plug to avoid

[D A

fresh contamination.
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III DIS M A N TLING / REA S S EM BLY

DISMANTLING

3.11 Connector "AK" - DFI1.20

The DFI1.20 is fitted with an "AK" type electrical

connector<;
This connector is indexed and press fitted into the
injector body.
This connector ensures the connection between the
engine harness and the injector coil.
It has an O ring on its base to seal the injector.

4]
1 -2p02y
If the connector is damaged, the YDT787 (DFI1.20 type
VW group) kit can be used to replace it as long as the
connector has not been twisted by more than +/- 5°
02 11o
out of alignment.
/2 29-C
04 ]n- c[ e
VNa
iv
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[D A

The C3I / C4I label must be removed to fit the

extraction tool.
If just the connector has to be replaced and the
internal components (Capnut, nozzle, CVA, ...) are to be
left undisturbed , it is recommended to carefully
remove this label.
Carefully prise up the plastic tabs in a circular fashion.
Apply a stream of hot air to soften the tabs.
If not, it will be necessary to print a new label (See
corresponding section)
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 DIS M A NTLIN G / REA S S EM BLY III

DISMANTLING
To extract the connector, position the half-shells and
the puller head around the connector.
Lightly tighten the half-shell bolt.
The final tightening will be done once the puller has
been fitted.
Place the injector in its mounting.

Position the puller bolt in contact with the head.

4]
Moderately tighten the half-shells.

1 -2p02y
(BTR bolt - 6 mm spanner).
Tighten the extractor bolt until the connector pops out.
02 11o
Adjust the tightness of the half-shell bolt to match the
/2 29-C
extraction effort.
Extract the connector and clean the connector socket.
Check that there is no O ring debris on the machined
04 ]n- c[ e

face of the injector.

VNa
iv
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[D A

Vital: Never reuse a connector module that has been extracted.

Once the connector has been removed, check the
condition of the coil contacts.
Vacuum and clean the socket to remove any debris.
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III DIS M A N TLING / REA S S EM BLY

DISMANTLING
If the injector connector was broken and the
preliminary electrical tests were not possible, carry
out the following tests :
• Insulation.
• Resistance.
• Inductance.
The YDT720 kit also assists these tests (See DDNX405
+ DT654 user manuals).

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
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[D A

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 DIS M A NTLIN G / REA S S EM BLY III

REPLACEMENT

4.1 Preliminary operations

Use only Delphi Technologies genuine parts when replacing faulty injector components and while carrying out
injector repairs. Effective repairs depend on the quality of the diagnostics previously carried out and on observance
of the method used to reassemble the new parts.
Once removed, visually inspect the condition of the following internal parts in order to check the source of the fault :
- Needle.
- Injector nozzle (check the part number marked on the part (See section on injector identification) and make
sure that it corresponds with the injector parts list).
- Needle spring.
- Valve and valve body (check the part number marked on the part and make sure it corresponds to the injector
parts list).
- Adapter plate (check that the part number marked on the part corresponds to the injector parts list) (it is only
fitted to the DFI1.1 to 1.4 injectors and the DFI2.3 injectors).
- Body of the injector.

4]
- Valve spring.

1 -2p02y
- Calibration pin.

Note:
02 11o
At this stage, the electrical part is assumed to be fully functioning. The coil must not be dismantled.
/2 29-C
Check for possible pollution from organic or metallic sources to locate the cause of the fault.
Wash and dry reusable internal mechanical parts. Next, check for traces of scratches, pitting, burring, dents,
04 ]n- c[ e

deformation and corrosion.

WARNING
Any part showing traces of damage must be replaced with a new part.
VNa

We recommend moving parts carefully to prevent scratching or deformation.

Any part that is dropped must be systematically discarded.
iv
el d
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[D A
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III DIS M A N TLING / REA S S EM BLY

REPLACEMENT

4.2 Replacing parts

4.2.1 Fault table

The table below provides details of faults that you should check for on the parts.

Set Part Faults

Particles in the feed slots
Dents and/or burring on the feed slots
Scratches
Damage to the needle cone
Needle
Burrs and/or deformation at the end of the
needle on the adapter plate side

4]
Traces of corrosion

1 -2p02y
Traces of seizure
Dents
Nozzle assembly
02 11o
Traces of leaks
/2 29-C
Scratches on the pressure faces
Corrosion on the pressure faces
04 ]n- c[ e

Injector body
Cracks around the HP hole
Presence of particles and/or chips
Scratches on the bore
VNa

Injection holes blocked

iv

Presence of particles in the coils

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Needle spring
Spring broken
[D A

Traces of leaks and scratches on the 'body'

polished face, corrosion on the 'adapter
Valve body plate' face.
Seat : Traces of leaks, scratches, corrosion
Valve
Pollution of the HP channel
Particles on the stem
Valve stem Seating taper : scratches, dents, traces of
leaks
Pressure faces: Traces of leaks and
Adapter plate (only fitted to scratches on the nozzle face, corrosion on
the DFI1.1 to 1.4 injector Adapter plate the valve face.
series)
Pollution of the HP channel
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 DIS M A NTLIN G / REA S S EM BLY III

REPLACEMENT

Set Part Faults

Mirror surface : Traces of leaks, deposits,
corrosion, scratches.
Body Dents
Pollution of the HP and/or of the backleak
Body of the injector. channel
Presence of particles in the coils
Spring
Spring broken
O ring Fuel leak
Positive pressure nipple O ring Fuel leak
Connector body Traces of impact damage
Connector module

4]
Electrical contacts Oxidation

1 -2p02y
4.2.2 Replacement procedure
02 11o
Refer to the preceding section Faults and parts replacement for internal parts.
/2 29-C
CAUTION
Reminder: As the dismantling procedure damages the nozzle cap, it must be automatically replaced.
The sealing washers 9001-850X must also be systematically replaced with new parts (see SIN DT412 in Direct
04 ]n- c[ e

Evolution) as must the snap rings (depending on the injector model).

VNa
iv
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[D A
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III DIS M A N TLING / REA S S EM BLY

REPLACEMENT

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
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[D A

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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY

5.1 Precautions before Assembly

The following cleanness guidelines must be observed before and during assembly of the injector:
Cleaning
All reusable parts must be washed in advance. Mechanical parts must all be washed in the ultrasonic cleaning unit
and the injector body must be thoroughly flushed.
Special attention must be paid to removing all traces of the adhesives from the threads (if necessary, use a
degreaser after brushing with the thread cleaner and check the condition of the threads at the end of the
operation). The nozzle holder body threads must be completely clean.
Drying
You must dry all of the washed parts to prevent any residual dirt. A blow gun can be used to remove any remnants of
dirt.

CAUTION
Take care not to push dirt into the parts or into the HP channels.

4]
Storage

1 -2p02y
The injector parts must be moved and stored in a clean overpressurised environment whilst awaiting assembly.

5.2 Injector Assembly

02 11o
/2 29-C
The cleanness conditions mentioned above must be
observed during assembly.
04 ]n- c[ e

Movable parts must be lubricated before assembly.

At this stage, the injector undergoing repair is
presumed to have no electrical faults.
Before starting assembly, check the position of the coil.
VNa
iv
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[D A
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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
5.2.1 Mesh filter - DFI1.5

Two configurations are possible for new mesh 1 2 3 4

filter assembly :
• Axial configuration in the M14.
≤ 5N.m

• Angled radial configuration in the M14.

Use the YDT786 kit for this assembly.
Axial configuration : 5 6

DDNX299D

YDT786

4]
Axial mesh filter - Complete assembly method

1 -2p02y
Prepare the YDT786 tool with the (G/H/I/J)
elements.
02 11o
Clean and lubricate the tool and the injector
/2 29-C
opening with ISO4113 fluid.
04 ]n- c[ e
VNa
iv
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[D A

Position the new mesh filter in the M14 opening.

The meshes are oriented to the exterior of the M14.
The 5 holes are oriented towards the interior of
the injector body.
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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY
Position the YDT786J guide tool.
Tighten the YDT786H.
The socket is centered in the injector M14.
Tighten the assembly and offer it up to the M14.

Make sure that the surface of the YDT786I

4]
pushrod is perfectly clean.

1 -2p02y
Engage the pushrod.
Engage and tighten the YDT786G until it bottoms
02 11o
out.
/2 29-C
04 ]n- c[ e
VNa
iv

Vital : do not force the pushrod thread or the tool

el d
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and the mesh filter will be damaged.

[D A

Loosen the pushrod thread.

Remove the tool from the M14.
Check the mesh filter position.
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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
Flush the injector body with 2 µm filtered
ISO4113 fluid.
Supply the injector M14 with ISO4113 fluid using
the YDT786E connector to eliminate any particles
contained in the HP channel.
Use a YDT542 or YDT546 connector plug to
protect the contacts and the injector coil during
this operation.
Plug the M14 with a new 9001-879A plug.

Angled radial configuration :

4]
1 2 3 4 5

1 -2p02y
≤ 2N.m

6 7
02 11o ±2mm
8 9 10
/2 29-C
≤ 5N.m
04 ]n- c[ e

11 12 13

DDNX299D
VNa

YDT786

Angled radial mesh filter - Complete assembly method

iv
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Prepare the YDT786 tool with the (G/K/L/M/N/O/

[D A

P) elements.
Clean and lubricate the tool with ISO4113 fluid.

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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY
Screw on and put the support in contact with the
YDT786L M14 connector.
Use the knurl on the operator side.
Important: be careful as there is a risk of cuts
from the threads.

Lubricate and position the YDT786N index socket

4]
on the HP connector cone.

1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv

Engage the YDT786O knurled nut but do not

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tighten it.
[D A

The YDT786N index socket must rotate freely.

Tighten the YDT786K centering barrel on the
YDT786N indexing socket.
(The barrel must just be in contact without
tightening)
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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
Lubricate and fit the YDT786P indexing pin.
Turn the assembly until the pin engages in the
mesh filter machined surface.
Tighten the YDT786O on its base.
Remove the YDT786K centering barrel with the
YDT786P pin.
(When removing the centering barrel, make sure
that the indexing ring does not move, if it does,
the indexing process must be repeated)

Position the new mesh filter in the M14 opening.

4]
The meshes are oriented to the exterior of the M14.

1 -2p02y
The 5 holes are oriented towards the interior of
the injector body.
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv

Lubricate and reposition the centering barrel

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YDT786K.
[D A

Make sure that the surface of the YDT786M

pushrod is perfectly clean.
Engage the pushrod.
Engage and tighten the YDT786G until it bottoms
out.
(Starting the fitting run requires a brief effort)

Vital :at the end of the run, do not force the pushrod thread or the tool and the mesh filter will be damaged.
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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY
Loosen the pushrod thread.
Remove the YDT786 tool in the reverse order.
Check the mesh filter position.

Example of an incorrectly fitted mesh filter.

4]
The mesh is marked and deformed.

1 -2p02y
The mesh must be replaced with a new one.
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv

Flush the injector body with 2 µm filtered

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ISO4113 fluid .
[D A

Supply the injector M14 with ISO4113 fluid using

the YDT786E connector to eliminate any particles
contained in the HP channel.
Use a YDT542 or YDT546 connector plug to
protect the contacts and the injector coil during
this operation.
Plug the M14 with a new 9001-879A plug.

Note:
If the new mesh filter is not correctly positioned, extract the filter, discard it and restart with a new filter.
Never reuse an extracted filter.
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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
5.2.2 Connector "AK" - DFI1.20
If the DFI1.20 connector module has been
removed, replace it with a new one.
Check the coil contacts in the injector body.
To fit a new connector module, position the
socket on the connector.

4]
1 -2p02y
Lubricate only the O ring with ISO4113 fluid
without allowing it to enter the injector body.
Place the connector module in the YDT787H
02 11o
fitting socket.
/2 29-C
Position the assembly in the support in contact
with the coil.
Place the [Link] bolt in contact.
04 ]n- c[ e

Tighten the bolt until the connector module has

been inserted into its base.
Loosen the bolt and remove the injector from the
tool.
VNa

Vital : The C3I / C4I label must only be fitted after

iv

the code has been printed.

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(See corresponding section).

[D A

5.2.3 Valve spring and calibration pin

The spring and pin in the nozzle holder body for
repair are factory matched to ensure precise L
calibration. These three parts must not be Calibration
separated.
pin

NHB
© BorgWarner Inc.

CAUTION
It is vital to refit paired parts or to use new parts from the Injector Bill Of Materials to conform to the correct
preloads with L=40µm.

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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY

Type of DFI1.3 / DFI2.3 DFI1.4 DFI1.5 / DFI2.5 DFI1.5.2 / DFI1.20 / DFI2.20

injector & HPC DFI2.5.2 & HPC
Preload 18 N. 22 N. 28 N. / 28.5 33 N. 33 N.
N. / 29 N.

If this criterion is not met, correct operation of the injector cannot be guaranteed.
If dismantled in advance, insert the calibration pin into the nozzle holder body housing provided.
If the pin is stepped, the big bore must be positioned outwards (spring side).

CAUTION
There are several classes or calibration pins and springs.
These are not interchangeable.
The spring (washed, dried and free of all contamination) must be inserted into the housing after the pin so

4]
that it is directly in contact with the valve.

1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
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[D A
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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
5.2.4 Valve / adapter plate assembly or CVA or SVA
In order to ensure correct injector operation, the assembly order of the valve / adapter plate for the DFI1.1 -
1.4 and the DFI2.3 injectors, or the CVA or the SVA for the DFI1.5 / DFI2.5 / DFI1.5.2 / DFI2.5.2 injectors, must
be strictly followed (Refer to the appendix in this document).
• Valve / Adapter plate assembly - DFI1.1 -
DFI1.4 and DFI2.3
The adapter plate is located between the
nozzle and the valve assembly. The valve
must be located on the coil side.

4]
1 -2p02y
02 11o
• Valve CVA or SVA - DFI1.5 / DFI2.5 /
/2 29-C
DFI1.5.2 / DFI2.5.2.
The valve must be located on the coil side.
04 ]n- c[ e
VNa
iv
el d
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[D A

© BorgWarner Inc.

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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY
5.2.5 Internal component assembly

• Apply at least 15 mg of Mobilith 220SHC

grease spread evenly across one of the
contact faces of the capnut / nozzle.
• Stack the internal parts in the correct order
and hand tighten the nut to ensure that
these stay in position.
• Fit the assembly into the YDT601 holder.
• Tighten the hand bar then the saddle nut to
lock it for the following operations.
(maximum torque on the nut is 22 Nm.)

4]
1 -2p02y
• Tighten the screw on the main holder to 5.5
Nm to compress the internal parts against
each other.
02 11o
The objective is to apply a 3000 N preload
/2 29-C
before tightening the capnut.
04 ]n- c[ e
VNa
iv
el d
ph

CAUTION
[D A

To improve injector performance (reduced valve seat distortion, reduced shear stress in the valve pins), the
preload has been increased to 3000 N (from the previous value of 500 N) to better seat the internal
components. To achieve this it is necessary to apply a torque of 5.5 Nm (equivalent to an effort of 3000 N).
This change has been applied to all solenoid injectors and is associated with the new tightening values (see
appendix) .
This preload must be applied to all Delphi Technologies solenoid injectors.
© BorgWarner Inc.

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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
5.2.6 Tightening the capnut

- Loosen the capnut.

- Put 2 drops of LOCTITE 243 adhesive (or
equivalent) on the capnut / NHB threads.
- Turn the injector 180° then repeat the
operation

4]
1 -2p02y
CAUTION
The nut and body threads must be free of all grease and other dirt.
The polymerization time for the adhesive is 10 minutes.
02 11o
/2 29-C
To fit the nut, the correct socket for each injector type must be used.

Type of Injectors with Injectors with Injectors with Injectors DFI1.5 Injectors with
04 ]n- c[ e

injector axial feed (with axial feed radial feed (Type Peugeot axial feed (with
backleak nipple) (without Citroen & Ford backleak nipple)
backleak nipple) DW10F Euro6)
VNa

Part YDT615 YDT643 YDT611 + YDT641 (A-B-C) YDT798

iv

number YDT612 +
YDT613
el d
ph

Illustrati
[D A

on

© BorgWarner Inc.

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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY

Type of injector Injectors DFI2.5 HPC Injectors DFI1.20

(Type TATA - 26 mm body) (Type VW / SEAT / SKODA / AUDI Euro6)
Part number YDT647 (A & B) YDT649 (A & B)
Illustration

Type of injector Injectors DFI2.20 Injectors DFI1.5.2 Injectors DFI2.5.2

(Type JCB - 19 mm body - (Type JAC - 19 mm body) (Type YUNNEI F40 / F45 -

4]
Tier4) Compatible with injectors Special body)

1 -2p02y
with nipple
Part number YDT717 (A & B) YDT798 YDT799 (A & B)
Illustration
02 11o
/2 29-C
04 ]n- c[ e
VNa

Injectors with axial feed

iv

• Position the injector on the main holder and

el d

carry out the operation described in the

ph

previous section.
[D A

• Connect the YDT437 / YDT643 sockets

respectively to the two sides of the injector.
• Tighten the capnut to the recommended
torque using a torque wrench (refer to the
appendix)
© BorgWarner Inc.

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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
• Finish tightening to the recommended angle
(refer to the appendix).

CAUTION
Align the index mark on the clamp YDT644 with
the 0 degree of the index ring or use the angular
tightening sector and then apply the indicated
tightening angle.

Conventional injectors with radial feed

4]
• Position the injector on the main holder and

1 -2p02y
carry out the operation described in the
previous section.
• Connect the YDT437 / YDT611 sockets
02 11o
respectively to the two sides of the injector.
/2 29-C
• Tighten the capnut to the recommended
torque using a torque wrench (refer to the
appendix)
04 ]n- c[ e
VNa
iv
el d

• Finish tightening to the recommended angle

ph

(refer to the appendix).

[D A

CAUTION
Align the index mark on the clamp YDT644 with
the 0 degree of the index ring or use the angular
tightening sector and then apply the indicated
tightening angle.
© BorgWarner Inc.

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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY
DFI1.5 injectors (type Peugeot Citroen & Ford DW10F Euro6) with radial feed
• Position the injector on the main holder and
carry out the operation described in the
previous section.
• Connect the YDT437 / YDT641 sockets
respectively to the two sides of the injector.
• Tighten the capnut to the recommended
torque using a torque wrench (refer to the
appendix)

4]
• Finish tightening to the recommended angle

1 -2p02y
(refer to the appendix).

CAUTION
02 11o
Align the mark on the saddle with the 0 degrees
/2 29-C
on the index ring then apply the recommended
angle.
04 ]n- c[ e
VNa
iv
el d
ph
[D A
© BorgWarner Inc.

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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
DFI2.5.2 injectors (type Yunnei F40 Euro4 / F45 Euro 5) with offset lateral feed</head>
• Warning, the position of the inlet does not
allow complete rotation of the body.
• Position the injector to allow rotation for
tightening the capnut.
• Connect the YDT437 / YDT641 sockets
respectively to the two sides of the injector.
• Tighten the capnut to the recommended
torque using a torque wrench (refer to the
appendix)
• If necessary, reposition the injector to allow
the final torque to be applied.

4]
• Finish tightening to the recommended angle

1 -2p02y
(refer to the appendix).

CAUTION
02 11o
Align the mark on the saddle with the 0 degrees
/2 29-C
on the index ring then apply the recommended
angle.
04 ]n- c[ e
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY
5.2.7 External components

Spherical washer and snap ring

Use the YDT443 pliers to fit the snap ring.
For PSA DW10 application NHBs, don't
forget to insert and clip the plastic C3I / C4I
code plate before fitting the injector clamp
(identification towards the top and opposite
the NHB connector). Fit the clamp with the
chamfer facing down to receive the
spherical thrust washer and the new snap
ring.

4]
1 -2p02y
External nut assembly (Gland-nut)
(Ford Puma and Yuchai 4W)
02 11o
This nut is assembled on the injector NHB
via the nozzle end of the injector:
/2 29-C
- Check that the external gland nut is fitted
with its snap ring. If this is not the case, use
the YDT444 sleeve for the assembly.
04 ]n- c[ e

Manually insert the snap ring into the nut

and then finish by pushing it into its
housing with YDT444 sleeve.
VNa
iv
el d
ph

- Protect the injector with the correct clean

[D A

caps and plugs from the YDT480 dispenser.

- Position the YDT447 injector holder in a vice.
- Position the injector on the YDT447 tool and
protect the injector nose with the YDT445
metal cap.
© BorgWarner Inc.

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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
- Place the external gland nut fitted with its
snap ring into position.
Using the YDT446 sleeve and a mallet, insert
the nut into the injector.

O-rings

4]
Depending on the injector type, the o-rings are fitted using a fitting cone.

1 -2p02y
• Hold the NHB and fit the o ring by hand.

Type of injector Other DFI1.x & DFI2.x Injectors DFI2.5 HPC Injectors DFI1.20
02 11o
type injectors except (Type TATA & Yuchai - (Type VW / SEAT /
/2 29-C
HPC 26 mm body) SKODA / AUDI )
(All applications)
04 ]n- c[ e

Part number YDT432 YDT647C YDT649E

Illustration
VNa
iv
el d
ph
[D A

The seal is fitted directly on the DFI1.20 backleak.

Plug the backleak immediately with a new
6407-631 plug.
© BorgWarner Inc.

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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY

5.3 Replacing the identification label

5.3.1 Adhesive label

The C2I/C3I/C4I code label must be stuck onto the

injector in its original location to finish the
assembly operation. The new code is vital for the
correct operation of the injector on the engine.
• The label can be printed using the label
printer, the DYMO LabelManager PC
program recommended by Delphi
Technologies and DYMO printer compatible
label reels adapted to the engine
compartment environment.
• The EPILOG laser engraving machine with
the YDT637 label support can be used to

4]
engrave the correction codes on the code

1 -2p02y
plates distributed by Delphi Technologies.

CAUTION
02 11o
To cut the label, simply position the reel on the support, choose the type of label to be engraved and the laser
/2 29-C
machine will automatically cut the label to the correct dimensions.

Recommended products: Polyester reinforced reel 9001-898.

04 ]n- c[ e

Use the 9001-899 heat shrink sleeve to protect

the label after sticking so that it remains legible
and properly stuck to the injector.
• Put the pre-cut strip on the label as shown
VNa

opposite.
iv

• Use a heat gun to shrink the sleeve.

el d
ph
[D A
© BorgWarner Inc.

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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY
5.3.2 Adhesive label- DFI2.5 HPC / 2.5.2 HPC
The C2I/C3I code label must be stuck onto the injector in its original location to finish the assembly operation.
Depending on the type of equipment used, two solutions are possible.
Solution with the DYMO 9001-898 label and its
LabelManager PC program recommended by
Delphi technologies with the label ribbons
adapted to the engine environment compatible
with the DYMO printer.
The C2I/C3I/C4I must be stuck under the injector
electrical connector and secured with the
9001-899 heat shrink tube.

4]
1 -2p02y
02 11o
Solution using the EPILOG laser with the YDT637
label support to print the correction code on the
/2 29-C
9001-907 labels distributed by Delphi
Technologies.
The injector repair is finalized by sticking the C2I/
04 ]n- c[ e

C3I/C4I label on the rear face behind the injector

electrical connector.

CAUTION
VNa

To cut the label, simply position the reel on the

support, choose the type of label to be engraved
iv

and the laser machine will automatically cut the

el d
ph

label to the correct dimensions.

[D A

5.3.3 Plastic code plate

Engrave the C3I / C4I correction on the blank code

plate using the EPILOG laser printer with the
YDT632 / YDT633 / YDT634 / YDT636 / YDT642.
support as appropriate.
• Position the code plate on the injector as
shown opposite.
• Carefully insert the pin into the injector.
© BorgWarner Inc.

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 DIS M A NTLIN G / REA S S EM BLY III

REASSEMBLY

Plate part 9308-328A 9308-330A 9308-320A 9308-328A 28273118 28328937

number 28241828 28241828
Plate image

Type of YDT632 YDT633 YDT634 YDT636 YDT642 YDT649C

support

4]
1 -2p02y
Example of Laser engraving on a DFI1.20 label:
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A
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III DIS M A N TLING / REA S S EM BLY

REASSEMBLY

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

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 AFTER THE REPA IR OPERA TION IV

AFTER THE REPAIR OPERATION

6.1 Post Repair Checks

Thorough bench tests must be carried out on every injector repaired. (See the appendix for the test bench supports
and fixings)
CR injectors must satisfy the following operational requirements:
- Coil resistance within the tolerances YDT720.
- External sealing.
- Internal sealing.
- Fuel deliveries within the tolerances.

When checking these criteria, you must follow the instructions below:

Coil resistance - YDT720

Coil 2 x 28 windings.
A T° = 20°C : 0.155 Ohm < R < 0.185 Ohm (0.160 Ohm < R < 0.190 Ohm for DFI1.5.2).
Insulation resistance > 10 MegOhm.

4]
1 -2p02y
Coil 1 x 56 windings.
At 20°C the resistance of the coil must be between 0.620 Ohm and 0.650 Ohm (Varies with temperature)
02 11o
Insulation resistance > 10 MegOhm.
/2 29-C
External and internal leakage test
Refer to section Diagnostics on the Bench.
04 ]n- c[ e

Fuel delivery and injector calibration

Install the injector on the bench whilst observing the necessary cleanness and tightening guidelines.
Select the type of injector to be tested.
Start the test.
VNa

The following parameters are measured automatically :

iv

- Opening delay. Refer to section Diagnostics on the Bench.

el d

- Fuel delivery. Refer to section Diagnostics on the Bench.

ph

Generate the correction code.

[D A

The correction code is generated by comparing the results for the injector tested with the reference curves.
The reference curves are generated on the test bench using new injectors with the same part numbers as the
injector repaired.
This operation is carried out prior to calibrating the repaired injector.

6.2 Repair Validation

Once the injector corrections have been generated, repeat a full test after entering this new code in IRIS.
If the test results are outside the tolerances, repeat the repair operation.
If the results are correct, continue the repair process by printing the identification label.

6.3 Repair Traceability

Print the new correction code using the label and printer recommended by Delphi Technologies.
The ID label contains the following information:
© BorgWarner Inc.

- Injector reference.
- Injector serial number.

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IV A FTER THE REPA IR OPERA TION

AFTER THE REPAIR OPERATION

- Correction code calculated in Aftermarket.
- ID of the Delphi Technologies distributor who performed the repair.
- Repair date.

For certain applications it may be necessary to print 2 different labels : one with only the correction codes and the
other with the rest of the information.

Note:
Aftermarket generated codes must also be written on the repair files handed to the customer and stored in the
vehicle. Each code must be linked to a serial number for the injector concerned and to the number of the cylinder to
which it is fitted.

6.4 Additional Operations

Finish the repair by fitting a new flameproof sealing washer 9001-850X (see SIN DT412 in Direct Evolution).
(Vital : for the steel flame-proof washers, they must be lubricated and stored in a VCI bag to avoid corrosion)

4]
Fit a new connector to the vehicle harness (make sure it corresponds to the injector parts list).

1 -2p02y
6.5 Measurement Equipment Maintenance
02 11o
The accuracy of the measurements carried out on the test bench depend on numerous factors:
/2 29-C
- The configuration of the test bench. Any modification during assembly or the addition of a component must be
validated by Delphi Technologies.
04 ]n- c[ e

- The test temperatures. You must observe the test fluid cooling recommendations to prevent any deviation
associated with the temperature.
- The quality of the test fluid. High temperature and high pressure commands can damage the quality of this
fluid. You must therefore monitor this parameter carefully and replace this fluid regularly. You are reminded
VNa

that this fluid must meet standard ISO 4113 and have a viscosity of between 2.45 and 2.75 cSt at 40°C.
Moreover, the replacement interval of the 2 µm filter must be observed to prevent dirt penetrating the
iv

injectors during the test.

el d
ph

You are reminded that the reliability of measurements depends on strict observance of the test conditions and
[D A

on the good working condition of the test equipment. It is therefore essential that you check that the bench
does not drift. Test the reference injectors (measure the flows and opening delays) at least once per week.
- Remember that the target files constitute the reference data for the tests.
- It is recommended that the targets are reset regularly. Do not wait for the files in IRIS to expire. © BorgWarner Inc.

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 AFTER THE REPA IR OPERA TION IV

AFTER THE REPAIR OPERATION

6.6 Storage

The injectors must be correctly stored after repair.

Cap the nozzle, the backleak and the inlet using the correct clean caps and plugs from the YDT480 / 9109-914 dispenser.

Part number : Use: Description :

9001-870A Protecting the backleak internal machining - All types

9001-872A Protecting the backleak nipple exterior - All types

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e

9001-879A Protecting the M14 - All types

VNa
iv
el d
ph
[D A

9001-880A Protecting the nozzle - All types

9001-855 Injector backleak for DFI1.5 and DFI1.5.2

© BorgWarner Inc.

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IV A FTER THE REPA IR OPERA TION

AFTER THE REPAIR OPERATION

Part number : Use: Description :

6407-631 DFI1.20 / DFI2.20 positive pressure injector backleak.

6407-638 DFI2.5 HPC (*) injector

(Diameter 26 mm - Yellow plug)

4]
1 -2p02y
6407-639 DFI2.5.2 HPC (*) injector
02 11o
/2 29-C
04 ]n- c[ e

6407-650 17mm diameter injector centralized backleak for the

VNa

DFI2.5.2.
iv
el d
ph
[D A

Several new part numbers have been added to the current range (See DT428 in Direct Evolution) :
Protect the electrical connector during storage using the connector plugs from the YDT540 dispenser (See DT460 in
Direct Evolution).
For DFI1.5 / DFI1.5.2 / DFI1.20 & DFI2.20 injectors with the plastic back-leak (For example : PSA, DC, VW, JCB...), the
machined surface must be lubricated with ORAPI CT615 grease (or equivalent) to avoid o ring damage.
depending on the application, exchange plastic connectors or backleak manifold assemblies are available.
For DFI2.5 HPC / DFI2.5.2 HPC / DFI2.5.2 injectors with the centralized backleak in the cylinder head (For example :
TATA, WEICHAI, YUNNEI "F40"...) , the injector machined surface must be lubricated with ORAPI CT615 grease (or
equivalent) to avoid o ring damage.
VCI sachets (9001-894, 9001-895 depending on the injector length) are also recommended to protect injectors
during storage.
Delphi Technologies can supply a packaging kit for repaired injectors with the part number 7135-606 (xx).
© BorgWarner Inc.

(xx is the abbreviation for the country)

This kit includes :
• A VCI sachet.

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 AFTER THE REPA IR OPERA TION IV

AFTER THE REPAIR OPERATION

• A label.
• A box with the Delphi Technologies image.

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A
© BorgWarner Inc.

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IV A FTER THE REPA IR OPERA TION

AFTER THE REPAIR OPERATION

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

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 A PPENDIC ES V

SCHEDULE

Labor Time
Sealing washer removal 2 min
Preliminary cleaning 5 min
Fitting the injector to the holder 3 min
Removing the identification label 1 min
Removing the gland nut - Ford Puma 4 min
Removing the capnut 4 min
Removing the internal components 2 min
Removing the DFI1.5 mesh filter 6 min
Refitting the DFI1.5 mesh filter 3 min

4]
Refitting the internal components 3 min

1 -2p02y
Fitting the capnut 4 min
Fitting the gland nut - Ford Puma / Yuchai 4W 3 min
02 11o
Removing the injector from the holder 2 min
/2 29-C
Fitting the identification label 2 min
Fitting the sealing washer 1 min
04 ]n- c[ e

Machine cycles Ultrasound Rinse Diagnostic cycle Characterization cycle

cleaning cleaning
VNa

Injector with C2I on AVM2PC 10 min 5 min 12 min - 1 injector only 17 min - 1 injector only
iv

Injector with C2I on CRIPC 1 10 min 5 min 10 min - 1 injector only 13 min - 1 injector only
el d

line
ph
[D A

Injector with C2I on CRIPC 4 10 min 5 min 6 min - 1 injector only 7 min - 1 injector only
line 7 min - 1 injector only 12 min - 1 injector only
Ford Puma Ford Puma
22 min - 4 injectors 27 min - 4 injectors
26 min - 4 injectors Ford 45 min - 4 injectors Ford
Puma Puma
Injector with C3I / C4I on 10 min 5 min 22 min - 1 injector only 40 min - 1 injector only
AVM2PC
Injector with C3I / C4I on 10 min 5 min 20 min - 1 injector only 33 min - 1 injector only
CRIPC 1 line
Injector with C3I / C4I on 10 min 5 min 8 min - 1 injector only 14 min - 1 injector only
CRIPC 4 line 30 min - 4 injectors 56 min - 4 injectors
© BorgWarner Inc.

CAUTION
The bench cycle times vary between injectors, so the figures in the table are average values.

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V A PPEN DIC ES

SCHEDULE

Type of injector Labor Cycles / type of machine Total

Total (in min and in
tenths of an hour)
Injector Injector with 36 min 29 min - 1 injector on AVM2PC 65 min 1.1
with C2I gland nut - Ford 23 min - 1 injector on CRIPC 1 line 59 min 1
Puma / Yuchai 4W
19 min - 1 injector on CRIPC 4 line 55 min 0.9
71 min - 4 injectors on CRIPC 4 107 min 1.8
line
Injector without 32 min 29 min - 1 injector on AVM2PC 65 min 1.1
gland nut 23 min - 1 injector on CRIPC 1 line 59 min 1
13 min - 1 injector on CRIPC 4 line 45 min 0.8
49 min - 4 injectors on CRIPC 4 81 min 1.4

4]
line

1 -2p02y
Injector with C3I 32 min 62 min - 1 injector on AVM2PC 94 min 1.6
53 min - 1 injector on CRIPC 1 line 85 min 1.4
02 11o
22 min - 1 injector on CRIPC 4 line 54 min 0.9
/2 29-C
86 min - 4 injectors on CRIPC 4 118 min 2
line
04 ]n- c[ e

Injector with C4I 32 min 42 min - 1 injector on AVM2PC 74 min 1.2

45 min - 1 injector on CRIPC 4 line 77 min 1.3
91 min - 4 injectors on CRIPC 4 123 min 2
VNa

line
iv
el d
ph
[D A

© BorgWarner Inc.

7-100 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

INJECTOR EXPLODED VIEW

8.1 Exploded view DFI1.1 to DFI1.4 & DFI2.3

CRI (013)
02 / 2010
1/1
150
140

4]
10

120
1 -2p02y
130

20

110
02 11o
128

30

/2 29-C

100
04 ]n- c[ e

90
VNa

80
iv

70
el d
ph
[D A

60
50
20
40
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 8-101

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

INJECTOR EXPLODED VIEW

8.2 Exploded view DFI1.5 / DFI1.5.2 / DFI2.5 / DFI2.5 HPC / DFI2.5.2 / DFI2.5.2 HPC

CRI (013)
06 / 2016
2/3
30

120
110
4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
90

160
30

60
50
VNa
iv
el d
ph
[D A

30
128

170

© BorgWarner Inc.

8-102 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

INJECTOR EXPLODED VIEW

8.3 Exploded view DFI1.20 / DFI2.20

CRI (013)
06 / 2016
3/3
4]

120
1 -2p02y
110
02 11o
/2 29-C
04 ]n- c[ e

90

160
30
VNa

60
50
iv
el d
ph
[D A
42

46
132
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 8-103

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

INJECTOR EXPLODED VIEW

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

8-104 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

REPAIR PROCEDURE SUMMARY

New parts and

N° Operations Rejected parts
consumables
1 Dismantle the flame arrester washer Washer YES
Complete injector if dent on
External visual inspection (scratches,
2a M14, on the tube or the nozzle YES
dents, leaks)
holder body.
Complete injector if connector
External visual check (DFI.20 electrical module is impact damaged and
2b YES
connector) twisted more than +/- 5° from
its initial position
3 External washing
4 Bench diagnostics (electric and hydraulic)

4]
Ford Puma injector : Removing the

1 -2p02y
5 External gland nut YES
external gland nut
6 Removing the label C2I/C3I/C4I Label C2I / C3I / C4I YES
02 11o
7 Removing the capnut Capnut YES
/2 29-C
Depending on the repair type:
- Mesh filter - (DFI1.5)
04 ]n- c[ e

- Valve assembly
8 Dismantling the injector. - Nozzle assembly
- Pin, valve spring
VNa

- Injector spring
iv

- O ring on the body

el d
ph

9 Visual inspection of non-rejected parts

[D A

10 Brushing the Injector threads

11 Wash all reusable parts
Checking the pressure face of the nozzle
12
holder body
13 Check the position of the coil
Inserting the calibration pin (if replaced) Pin and spring (if
14
and the valve spring replaced)
15 Greasing the nut Grease
Assembling the internal parts (injector Internal parts
16
assembly, valve, spacer, springs) changed
17 Compressing the stack of internal parts Application of 3000 N.
LOCTITE 243
18 Deposit adhesive on the threads
adhesive.
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 9-105

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

REPAIR PROCEDURE SUMMARY

New parts and

N° Operations Rejected parts
consumables
Screwing the capnut on and and
19 tightening to the torque and angle
recommended
Assembling the external gland nut (Puma
External gland nut
20 injector) or snap ring (Citroen injector) or
and snap ring
the O ring
Fitting of external parts (o-rings on body,
21 YES
backleak ...)
Bench tests : electrical, static and
22
dynamic leakage
23 Characteristics of the injector.

4]
1 -2p02y
24 Generate the correction code
Flame proof washer -
25 Assemble the flame arrester washer
DT412
02 11o
26 Printing and applying the label Label / Sleeve / Plate
/2 29-C
Protective caps, VCI
27 Cap and pack sachets and
04 ]n- c[ e

packaging.
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

9-106 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
EJBR00801Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5611 + and 1
9733140 AHP5010
M8x40
EJBR00901Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR01001A NTA5610 + YES AHP5009 NA NTA53 A089E96 A089E965 NA

4]
NTA5614 + and 03 1

1 -2p02y
9733147 AHP5010
M8x90
02 11o
EJBR01001Z NTA5610 + YES AHP5009 NA NTA53 A089E96 A089E965 NA
/2 29-C
NTA5614 + and 03 1
9733147 AHP5010
M8x90
04 ]n- c[ e

EJBR01101Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

NTA5611 + and 1
9733140 AHP5010
VNa

M8x40
iv

EJBR01201Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

9733138 and 1
el d
ph

M8x30 AHP5010
[D A

EJBR01301Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

NTA5611 + and 1
9733140 AHP5010
M8x40
EJBR01302Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5611 + and 1
9733140 AHP5010
M8x40
EJBR01401Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
EJBR01501Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 10-107

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
EJBR01601Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5611 + and 1
9733140 AHP5010
M8x40
EJBR01701Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
EJBR01801A NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1

4]
M8x30 AHP5010

1 -2p02y
EJBR01801Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
02 11o
EJBR01901Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
/2 29-C
NTA5612 + and 1
9733143 AHP5010
04 ]n- c[ e

M8x55
EJBR02001Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5611 + and 1
9733140 AHP5010
VNa

M8x40
iv

EJBR02101Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

el d
ph

9733138 and 1
[D A

M8x30 AHP5010
EJBR02201Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5611 + and 1
9733140 AHP5010
M8x40
EJBR02301Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR02401Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR02501Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
© BorgWarner Inc.

9733143 AHP5010
M8x55

10-108 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
EJBR02601Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
M8x80
EJBR02701Z NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
EJBR02801D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1

4]
9733143 AHP5010

1 -2p02y
M8x55
EJBR02901D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
02 11o
9733143 AHP5010
/2 29-C
M8x55
EJBR03001D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
04 ]n- c[ e

NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR03101D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
VNa

9733138 and 1
iv

M8x30 AHP5010
el d
ph

EJBR03201D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

[D A

NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR03301D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR03401D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
M8x80
EJBR03501D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010
M8x55
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 10-109

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
EJBR03601D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR03701D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR03801D NTA5650 + YES AHP5009 NA NA A089E96 A089E965 NA

4]
9733149 and 1

1 -2p02y
M8x100 AHP5010
EJBR03901D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
02 11o
9733143 AHP5010
/2 29-C
M8x55
EJBR03902D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
04 ]n- c[ e

NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR04001D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
VNa

9733138 and 1
iv

M8x30 AHP5010
el d
ph

EJBR04101D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

[D A

9733138 and 1
M8x30 AHP5010
EJBR04201D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5651 + and 1
9733145 AHP5010
M8x70
EJBR04301D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
M8x80
EJBR04401D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
M8x80
EJBR04501D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
© BorgWarner Inc.

NTA5613 + and 1
AHP5010

10-110 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
9733146
M8x80
EJBR04601D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
M8x80
EJBR04701D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
M8x80

4]
1 -2p02y
EJBR04901D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
02 11o
M8x80
/2 29-C
EJBR05001D NTA5644 + YES AHP5009 NA NA A089E96 A089E965 NA
9733142 and 1
04 ]n- c[ e

M8x50 AHP5010
EJBR05101D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
VNa

EJBR05102D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

iv

9733138 and 1
el d
ph

M8x30 AHP5010
[D A

EJBR05201D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

9733138 and 1
M8x30 AHP5010
EJBR05301D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
EJBR05401D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010
M8x55
EJBR05501D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010
M8x55
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 10-111

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
EJBR05601D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
EJBR05701D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
M8x80
EJBR06001D NTA5650 + YES AHP5009 NA NA A089E96 A089E965 NA
9733149 and 1

4]
M8x100 AHP5010

1 -2p02y
EJBR06101D NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
02 11o
EJBR06201D NTA5610 + YES AHP5009 NA NTA53 A089E96 A089E965 NA
/2 29-C
NTA5655 and 03 1
AHP5010
04 ]n- c[ e

EJDR00001Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA

9733138 and 03 1
M8x30 AHP5010
VNa

EJDR00002Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA

9733138 and 03 1
iv

M8x30 AHP5010
el d
ph

EJDR00101Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA

[D A

9733138 and 03 1
M8x30 AHP5010
EJDR00201Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
9733138 and 03 1
M8x30 AHP5010
EJDR00202Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
9733138 and 03 1
M8x30 AHP5010
EJDR00301Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
9733138 and 03 1
M8x30 AHP5010
EJDR00401Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
9733138 and 03 1
M8x30 AHP5010
© BorgWarner Inc.

10-112 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
EJDR00402Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
9733138 and 03 1
M8x30 AHP5010
EJDR00403Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
9733138 and 03 1
M8x30 AHP5010
EJDR00501Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
NTA5609 + and 03 1
9733140 AHP5010

4]
M8x40

1 -2p02y
EJDR00502Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
NTA5609 + and 03 1
9733140 AHP5010
02 11o
M8x40
/2 29-C
EJDR00503Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
NTA5609 + and 03 1
04 ]n- c[ e

9733140 AHP5010
M8x40
EJDR00504Z NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
NTA5609 + and 03 1
VNa

9733140 AHP5010
iv

M8x40
el d
ph

EJDR00601D NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA

[D A

NTA5609 + and 03 1
9733140 AHP5010
M8x40
EJDR00701D NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
NTA5609 + and 03 1
9733140 AHP5010
M8x40
EJDR00801D NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
NTA5609 + and 03 1
9733140 AHP5010
M8x40
EJDR01001D NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
9733138 and 03 1
M8x30 AHP5010
EJDR01101D NTA5608 + NO AHP5009 NA NTA53 A089E96 A089E965 NA
© BorgWarner Inc.

9733138 and 03 1
M8x30 AHP5010

DDNX299G(EN) - Issue 1 of 10/2020 10-113

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
EMBR00001 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
D NTA5711 + and 08 0
NTA5713 AHP5214
EMBR00002 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
D NTA5711 + and 08 0
NTA5713 AHP5214
EMBR00101 NTA5705 + YES AHP5009 NA NTA53 A089E96 A089E965 NA
D NTA5651 and 08 1
AHP5010

4]
EMBR00101 NTA5705 + YES AHP5009 NA NTA53 A089E96 A089E965 NA

1 -2p02y
DP NTA5651 and 08 1
02 11o AHP5010
EMBR00201 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
D NTA5714 + to 0
/2 29-C
NTA5715 AHP5214
EMBR00202 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
04 ]n- c[ e

D NTA5714 + to 0
NTA5715 AHP5214
EMBR00203 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
VNa

D NTA5714 + to 0
NTA5715 AHP5214
iv

EMBR00301 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA

el d
ph

D NTA5715 + to 0
[D A

NTA5720 AHP5214
28229873 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5722 + and 0
NTA5717 AHP5214
28229876 NTA5724 YES AHP5009 NA NTA53 A089E96 A089E965 NA
and 08 1
AHP5010
28230326 NTA5734 + YES AHP5234 AHP5225 NA A089E96 A089E965 NA
NTA5682 + to 1
NTA5414 + AHP5237
NTA5507 +
9733145
M8x70
28230673 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
© BorgWarner Inc.

NTA5612 + and 1
AHP5010

10-114 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
9733143
M8x55
28230891 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0
NTA5713 AHP5214
28231014 NTA5725 + YES AHP5009 NA NA A129A11 A129P111 NA
NTA5612 and 0
AHP5010
28231462 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA

4]
NTA5718 + and 08 0

1 -2p02y
NTA5719 AHP5214
28232234 NTA5610 +02 11o YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
/2 29-C
28232242 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
04 ]n- c[ e

M8x30 AHP5010
28232248 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
VNa

28232251 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

iv

9733138 and 1
el d
ph

M8x30 AHP5010
[D A

28234058 NTA5709 + YES AHP5211 AHP5225 NA A089E96 A089E965 NA

NTA5710 and 1
AHP5214
28235143 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5714 + to 0
NTA5715 AHP5214
28236381 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5722 + and 0
NTA5723 AHP5214
28237259 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
9733138 and 1
M8x30 AHP5010
28239766 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5716 + and 0
© BorgWarner Inc.

NTA5717 AHP5214

DDNX299G(EN) - Issue 1 of 10/2020 10-115

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28239769 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5716 + and 0
NTA5717 AHP5214
28240130 NTA5610 + YES AHP5009 NA NTA53 A089E96 A089E965 NA
NTA5655 and 03 1
AHP5010
28240131 NTA5610 + YES AHP5009 NA NTA53 A089E96 A089E965 NA
NTA5655 and 03 1
AHP5010

4]
28242659 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

1 -2p02y
NTA5613 + and 1
9733146 AHP5010
M8x80
02 11o
28247584 NTA5768 + YES AHP5246 NA NTA53 A089E96 A089E965 NA
/2 29-C
NTA5651 and 03 1
AHP5247
04 ]n- c[ e

28253155 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

NTA5612 + and 1
9733143 AHP5010
M8x55
VNa

28258683 NTA5644 YES AHP5009 NA NA A089E96 A089E965 NA

iv

and 1
el d
ph

AHP5010
[D A

28262295 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

NTA5613 + and 1
9733146 AHP5010
M8x80
28264951 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5716 + and 0
NTA5717 AHP5214
28264952 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5716 + and 0
NTA5717 AHP5214
28269978 NTA5726 YES AHP5009 NA NA A089E96 A089E965 NA
and 1
AHP5010
28270450 NTA5724 YES AHP5246 NA NTA53 A089E96 A089E965 NA
© BorgWarner Inc.

and 08 1
AHP5247

10-116 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28271551 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0
NTA5713 AHP5214
28272472 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0
NTA5713 AHP5214
28280576 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010

4]
M8x80

1 -2p02y
28280600 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
02 11o
M8x80
/2 29-C
28288104 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
04 ]n- c[ e

9733146 AHP5010
M8x80
28288930 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5759 + and 1
VNa

M8x35 AHP5010
iv

28292089 NTA5724 YES AHP5246 NA NTA53 A089E96 A089E965 NA

el d
ph

and 08 1
[D A

AHP5247
28301796 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 NA
NTA5709 + to 5
NTA5776 AHP5263
28307309 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0
NTA5713 AHP5214
28308684 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5714 + to 0
NTA5715 AHP5214
28308779 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0
NTA5713 AHP5214
28317158 NTA5724 YES AHP5246 NA NTA53 A089E96 A089E965 NA
© BorgWarner Inc.

and 08 1
AHP5247

DDNX299G(EN) - Issue 1 of 10/2020 10-117

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28319895 NTA5732 + YES AHP5230 AHP5225 YDT711 A129A11 A129P111 NA
NTA5733 + to 0
NTA5682 AHP5233
28319898 NTA5732 + YES AHP5230 AHP5225 YDT711 A129A11 A129P111 NA
NTA5733 + to 0
NTA5682 AHP5233
28320083 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5612 + and 1
9733143 AHP5010

4]
M8x55

1 -2p02y
28320793 NTA5726 YES AHP5009 NA NA A089E96 A089E965 NA
and 1
AHP5010
02 11o
28332075 NTA5724 YES AHP5246 NA NTA53 A089E96 A089E965 NA
/2 29-C
and 08 1
AHP5247
04 ]n- c[ e

28332705 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA

NTA5714 + to 0
NTA5715 AHP5214
VNa

28334532 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA

NTA5711 + and 08 0
iv

NTA5713 AHP5214
el d
ph

28337917 NTA5709 + YES AHP5211 AHP5225 NA A089E96 A089E965 NA

[D A

NTA5710 and 1
AHP5214
28338840 NTA5734 + YES AHP5234 AHP5225 NA A089E96 A089E965 NA
NTA5682 + to 1
NTA5414 + AHP5237
NTA5507 +
9733145
M8x70
28342997 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0
NTA5713 AHP5214
28343002 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0
NTA5713 AHP5214
© BorgWarner Inc.

10-118 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28347042 NTA5709 + YES AHP5211 AHP5225 NA A089E96 A089E965 NA
NTA5710 and 1
AHP5214
28348370 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0
NTA5713 AHP5214
28348371 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0
NTA5713 AHP5214

4]
28359042 NTA5726 YES AHP5009 NA NA A089E96 A089E965 NA

1 -2p02y
and 1
02 11o AHP5010
28370681 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the
NTA5709 + to 5 HJ081
/2 29-C
NTA5776 AHP5263 tools on
the AVM2
04 ]n- c[ e

with the
pump :
2831300
0
VNa

28379457 NTA5724 YES AHP5009 NA NTA53 A089E96 A089E965 NA

iv

and 08 1
el d
ph

AHP5010
[D A

28382353 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

NTA5612 + and 1
9733143 AHP5010
M8x55
28384645 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5715 + to 0
NTA5720 AHP5214
28386106 NTA5709 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5714 + and 1
NTA5715 AHP5010
28387256 NTA5726 YES AHP5009 NA NA A089E96 A089E965 NA
and 1
AHP5010
28387604 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5715 + to 0
© BorgWarner Inc.

NTA5720 AHP5214

DDNX299G(EN) - Issue 1 of 10/2020 10-119

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28388960 NTA5732 + YES AHP5230 AHP5225 YDT711 A129A11 A129P111 NA
NTA5733 + to 0
NTA5682 AHP5233
28389783 NTA5759 + YES AHP5230 AHP5225 YDT797 A129A11 A129P111 NA
NTA5709 + to 0
YDT914 AHP5233
28397569 NTA5722 + YES AHP5009 NA NA A129A11 A129P111 NA
NTA5709 + and 0
NTA5717 AHP5010

4]
28400214 NTA5725 + YES AHP5009 NA NA A129A11 A129P111 NA

1 -2p02y
NTA5612 and 0
02 11o AHP5010
28407560 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
/2 29-C
9733146 AHP5010
M8x80
04 ]n- c[ e

28424049 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 NA

NTA5709 + to 5
NTA5776 AHP5263
VNa

28437695 YDT922B + YES AHP5066 NA NA A089E97 A129P111 NA

YDT922A (fuel Flexible 3
iv

sleeve) pipes
el d
ph

Cleaning
[D A

flexible
pipes :
See the
note
below
28458380 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
M8x80
28457614 NTA5705 + YES AHP5246 NA NA A129A11 A129P111 NA
NTA5612 and 0
AHP5247
28457628 NTA5705 + YES AHP5246 NA NA A129A11 A129P111 NA
NTA5612 and 0
AHP5247
© BorgWarner Inc.

10-120 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28463904 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA
NTA5613 + and 1
9733146 AHP5010
M8x80
28466774ES NTA5705 + YES AHP5009 NA NTA53 A089E96 A089E965 NA
NTA5651 and 08 1
AHP5010
28475604 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the
NTA5709 + to 5 HJ081

4]
NTA5776 AHP5263 tools on

1 -2p02y
the AVM2
with the
pump :
02 11o
2831300
/2 29-C
0
28475606 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the
04 ]n- c[ e

NTA5709 + to 5 HJ081
NTA5776 AHP5263 tools on
the AVM2
with the
VNa

pump :
iv

2831300
0
el d
ph

28489548 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA

[D A

NTA5716 + to 0
NTA5717 AHP5214
28489562 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5716 + to 0
NTA5717 AHP5214
28490086 NTA5709 + YES AHP5009 NA NA A129A11 A129P111 NA
NTA5714 and 0
AHP5010
28492677 NTA5732 + YES AHP5228 AHP5225 YDT711 A129A11 A129P111 NA
NTA5733 + to 0
NTA5682 AHP5231
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 10-121

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28506046 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the
NTA5709 + to 5 HJ081
NTA5776 AHP5263 tools on
the AVM2
with the
pump :
2831300
0
28521738 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the
NTA5709 + to 5 HJ081

4]
NTA5776 AHP5263 tools on

1 -2p02y
the AVM2
with the
02 11o pump :
/2 29-C
2831300
0
04 ]n- c[ e

28529434 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the

NTA5709 + to 5 HJ081
NTA5776 AHP5263 tools on
the AVM2
VNa

with the
pump :
iv

2831300
el d
ph

0
[D A

28530129 NTA5610 + YES AHP5009 NA NA A089E96 A089E965 NA

NTA5613 + and 1
9733146 AHP5010
M8x80
28534718 NTA5725 + YES AHP5009 NA NA A129A11 A129P111 NA
NTA5612 and 0
AHP5010
28535488 NTA5776 + YES AHP5009 NA NA A129A11 A129P111 NA
NTA5709 + and 0
NTA5759 AHP5010
28540276 NTA5709 + YES AHP5211 AHP5225 NA A129A11 A129P111 NA
NTA5714 + to 0
NTA5715 AHP5214
© BorgWarner Inc.

10-122 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28543147 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the
NTA5709 + to 5 HJ081
NTA5776 AHP5263 tools on
the AVM2
with the
pump :
2831300
0
28548932 NTA5709 + YES AHP5211 AHP5225 NTA53 A129A11 A129P111 NA
NTA5711 + and 08 0

4]
NTA5713 AHP5214

1 -2p02y
28565330 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the
NTA5709 + to 5 HJ081
02 11o
NTA5776 AHP5263 tools on
/2 29-C
the AVM2
with the
pump :
04 ]n- c[ e

2831300
0
28565335 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 NA
VNa

NTA5709 + to 5
iv

NTA5776 AHP5263
el d

28565336 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the

ph

NTA5709 + to 5 HJ081
[D A

NTA5776 AHP5263 tools on

the AVM2
with the
pump :
2831300
0
28565337 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the
NTA5709 + to 5 HJ081
NTA5776 AHP5263 tools on
the AVM2
with the
pump :
2831300
0
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 10-123

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28565339 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the
NTA5709 + to 5 HJ081
NTA5776 AHP5263 tools on
the AVM2
with the
pump :
2831300
0
28570880 YDT922B + YES AHP5066 NA NA A089E97 A129P111 NA
YDT922A (fuel 3

4]
Flexible
sleeve)

1 -2p02y
pipes
Cleaning
flexible
02 11o pipes :
/2 29-C
See the
note
below
04 ]n- c[ e

28577054 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the

NTA5709 + to 5 HJ081
NTA5776 AHP5263 tools on
VNa

the AVM2
with the
iv

pump :
el d
ph

2831300
[D A

0
28580673 NTA5759 + YES AHP5230 AHP5225 YDT797 A129A11 A129P111 NA
NTA5709 + to 0
YDT914 AHP5233
28589920 NTA5726 YES AHP5009 NA NA A089E96 A089E965 NA
and 1
AHP5010
28602948 NTA5732 + YES AHP5228 AHP5225 YDT711 A129A11 A129P111 NA
NTA5733 + to 0
NTA5682 AHP5231
28602949 NTA5732 + YES AHP5228 AHP5225 YDT711 A129A11 A129P111 NA
NTA5733 + to 0
NTA5682 AHP5231
© BorgWarner Inc.

10-124 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TEST BENCH HOLDERS AND FITTING

Part number Clamping Spacer HP pipe HP pipe Backlea Control Resistanc Other
block and NTA50 Adapters k Cable e Cable Tools
spacer 02 connec
tor
28651415 YDT922B + YES AHP5066 NA NA A089E97 A129P111 NA
YDT922A (fuel Flexible 3
sleeve) pipes
Cleaning
flexible
pipes :
See the
note
below
28654963 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the

4]
NTA5709 + to 5 HJ081

1 -2p02y
NTA5776 AHP5263 tools on
the AVM2
02 11o with the
/2 29-C
pump :
2831300
0
04 ]n- c[ e

28654965 NTA5651 + YES AHP5260 NA YDT797 A089E97 A089E974 Using the

NTA5709 + to 5 HJ081
NTA5776 AHP5263 tools on
VNa

the AVM2
with the
iv

pump :
el d
ph

2831300
[D A

0
28657626 NTA5732 + YES AHP5228 AHP5225 YDT711 A129A11 A129P111 NA
NTA5733 + to 0
NTA5682 AHP5231
28670622 NTA5725 + YES AHP5009 NA NA A129A11 A129P111 NA
NTA5612 and 0
AHP5010
42014420 NTA5726 YES AHP5009 NA NA A089E96 A089E965 NA
and 1
AHP5010

CAUTION
Cleaning flexible pipes
Folding and straightening of flexible pipes may lead to an accumulation of particles inside the pipes.
Although the number of particles can be below those sufficient to cause damage, as these pipes are twisted when
© BorgWarner Inc.

fitting to the injector or the rail, it is recommended to flush them using the Hartridge Ultrarinse tank (HM1009)
before fitting and using them.

DDNX299G(EN) - Issue 1 of 10/2020 10-125

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TEST BENCH HOLDERS AND FITTING

This process will flush all contaminating particles due to twisting and eliminate all contamination during tests.

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

10-126 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TIGHTENING TORQUES

Preload (N)
Pre-tightening Maximum permitted torque
Part number (kit YDT645 Angle (°)
(Nm) (Nm)
required)
EJBR00801Z
EJBR00901Z
EJBR01101Z
EJBR01201Z
EJBR01301Z
EJBR01302Z
EJBR01401Z
EJBR01501Z
EJBR01601Z

4]
1 -2p02y
EJBR01701Z
EJBR01801Z
EJBR01801A
02 11o
EJBR01901Z
/2 29-C
EJBR02001Z
EJBR02101Z
04 ]n- c[ e

EJBR02201Z 3000
EJBR02301Z (kit YDT645 20 +/- 2 39 +/- 4 60
EJBR02401Z required)
VNa

EJBR02501Z
iv

EJBR02601Z
el d

EJBR02701Z
ph
[D A

EJBR02801D
EJBR02901D
EJBR03001D
EJBR03101D
EJBR03201D
EJBR03301D
EJBR03401D
EJBR03501D
EJBR03601D
EJBR03701D
EJBR03901D
EJBR03902D
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 11-127

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TIGHTENING TORQUES

Preload (N)
Pre-tightening Maximum permitted torque
Part number (kit YDT645 Angle (°)
(Nm) (Nm)
required)
EJBR04001D
EJBR04101D
EJBR04201D
EJBR04301D
EJBR04401D
EJBR04501D
EJBR04601D
EJBR04701D
EJBR04901D

4]
EJBR05001D

1 -2p02y
EJBR05101D
EJBR05102D 02 11o
EJBR05201D
/2 29-C
EJBR05301D
3000
EJBR05501D
(kit YDT645 20 +/- 2 39 +/- 4 60
04 ]n- c[ e

EJBR05601D
required)
EJBR05701D
EJBR06101D
28230673
VNa

28240130
iv

28240131
el d
ph

28253155
[D A

28280600
28288104
28288930
28320083
28382353
28384443
28407560
28530129
© BorgWarner Inc.

11-128 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TIGHTENING TORQUES

Preload (N)
Pre-tightening Maximum permitted torque
Part number (kit YDT645 Angle (°)
(Nm) (Nm)
required)
EJDR00001Z
EJDR00002Z
EJDR00101Z
EJDR00201Z
EJDR00202Z
EJDR00301Z
EJDR00401Z
EJDR00402Z
EJDR00403Z
3000

4]
EJDR00501Z
(kit YDT645 20 +/- 2 29 +/- 4 55

1 -2p02y
EJDR00502Z
required)
EJDR00503Z 02 11o
EJDR00504Z
/2 29-C
EJDR00601D
EJDR00701D
04 ]n- c[ e

EJDR00801D
EJBR01001A
EJBR01001Z
EJDR01001D
VNa

EJDR01101D
iv

EJBR03801D 3000
el d
ph

EJBR06001D (kit YDT645 20 +/- 2 35 +/- 4 55

[D A

28247584 required)
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 11-129

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TIGHTENING TORQUES

Preload (N)
Pre-tightening Maximum permitted torque
Part number (kit YDT645 Angle (°)
(Nm) (Nm)
required)
EMBR00001D
EMBR00002D
EMBR00101D
EMBR00101DP
EMBR00301D
28229876
28230891
28231014
28234058

4]
28239766

1 -2p02y
28239769
28264951 02 11o
28264952
/2 29-C
28269978
3000
28270450
(kit YDT645 20 +/- 2 44 +/- 2 60
04 ]n- c[ e

28271551
required)
28272472
28307309
28308779
VNa

28317158
iv

28320793
el d
ph

28334532
[D A

28338840
28342997
28347042
28348370
28378371
28379457
28463904
28535488
© BorgWarner Inc.

11-130 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

TIGHTENING TORQUES

Preload (N)
Pre-tightening Maximum permitted torque
Part number (kit YDT645 Angle (°)
(Nm) (Nm)
required)
28338840
28386106
28437695
28457614 3000
28457628 (kit YDT645 20 +/- 2 44 +/- 4 60
28458380 required)
28490086
28534718
28548932

4]
3000

1 -2p02y
28262295 (kit YDT645 20 +/- 2 45 +/- 4 60
required)
02 11o
3000
/2 29-C
28466774ES (kit YDT645 20 +/- 2 50 +/- 4 60
required)
04 ]n- c[ e

EMBR00201D
EMBR00202D
EMBR00203D
28229873
VNa

28236381
iv

28231462
el d
ph

28235143
[D A

28292089
28319895
28319898 3000
28337917 (kit YDT645 20 +/- 2 64 +/- 2 67
28359042 required)
28387256
28388960
28422374
28424049
28492677
28540276
28602948
28602949
© BorgWarner Inc.

28657626

DDNX299G(EN) - Issue 1 of 10/2020 11-131

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

TIGHTENING TORQUES

Preload (N)
Pre-tightening Maximum permitted torque
Part number (kit YDT645 Angle (°)
(Nm) (Nm)
required)
3000
28397569
(kit YDT645 20 +/- 2 64 +/- 4 67
28570880
required)
28370681
28474999
28475604
28475606
28506046
28521738 3000

4]
28543147 (kit YDT645 20 +/- 2 64 +/- 2 75

1 -2p02y
28565330 required)
28565336 02 11o
28565337
/2 29-C
28565339
28654963
28654965
04 ]n- c[ e

3000
28389783 (kit YDT645 12 +/- 0.5 78 +/- 2 75
required)
VNa

28529434
iv

28577054
el d
ph

28580673 3000
[D A

28588785 (kit YDT645 12 +/- 0.5 50 +/- 2 68

28589920 required)
28632368
42014420
3000
28384645
(kit YDT645 12 +/- 0.5 80 +/- 2 80
28387604
required)
© BorgWarner Inc.

11-132 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
 A PPENDIC ES V

NOTES

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A
© BorgWarner Inc.

DDNX299G(EN) - Issue 1 of 10/2020 12-133

Delphi Technologies is a Brand of BorgWarner Inc.
V A PPEN DIC ES

NOTES

4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A

© BorgWarner Inc.

12-134 DDNX299G(EN) - Issue 1 of 10/2020

Delphi Technologies is a Brand of BorgWarner Inc.
Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.
Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.
Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie sofort reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its productrange.
einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen. All Rights Reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,
Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores, recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.
tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar la
piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel,
consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad.

Do not put your skin into the fuel jets under pressure, especially those due to pressure
pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injection
under the skin, contact a doctor immediately. Please refer to the health and security fuel
documents. Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd., mais
la société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd. poursuit un programme intensif de conception et de développement
Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux qui peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd. se réserve le droit de modifier les spécifications, sans pré-
provenant des fuites de tuyaux et des joints soumis à la haute pression. Le liquide sous avis et si cela est nécessaire, pour assurer les performances optimales de sa gamme de produits.
Tous droits réservés
haute pression injecté sous la peau peut causer des blessures mortelles. En cas
Toute reproduction, mémorisation dans un système informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen électronique,
d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de mécanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation préalable de Delphi Diesel Systems Ltd.
santé et de sécurité du gazole.
Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione,
specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione

]
possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare

24
immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

y
Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen

1 p
20
Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità per
onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder eventuali imprecisioni. Delphi Diesel Systems Ltd. svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto.
hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als

02 o
Delphi Diesel Systems Ltd. si riserva il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini assicurare le prestazioni

-
de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezon- ottimali dalla sua gamma di prodotti.

11

/2 C
dheids-en veiligheidsfiche met betrekking tot de brandstof.z Tutti i diritti riservati
Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo,
Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a elettronico, di fotocopiatura, di registrazione o altro, senza previa autorizzazione di Delphi Diesel Systems Ltd.

9-
fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentos

04 nce
mortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte

[2
or favor a documentação respeitante a saúde e segurança de combustíveis.

-
Schutzbrille/Gesichtsschutz tragen. Proteggersi gli occhi/la faccia.

N]

va
Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd. no acepta ninguna responsabilidad legal
por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd. se sigue un programa intensivo de diseño e investigación el cual podría

iV
Úsese protección para los ojos/la cara. Veiligheidsbril/-masker gebruiken. en cualquier momento alterar la especificación de los productos. Delphi Diesel Systems Ltd. se reserva el derecho de alterar las especificaciones
sin notificación previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos.

Ad
ph
Todos los Derechos Reservados
Wear eye/face protection. Use protecção da face/olhos. No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia,
grabación o cualquier otro, sin autorización previa de Delphi Diesel Systems Ltd.
el
Porter un appareil de protection
[D

des yeux / du visage.

Von Zündquellen fernhalten Conservare lontano da fiamme

- Nicht rauchen. e scintille - Non fumare.
Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel Systems
Conservar alejado de toda llama Ver van open vuur en ontstekingsbronnen Ltd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein forlaufendes Design
o fuentede chispas - No fumar. houden - Niet reken. und Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produkdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne
Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen.
Alle Rechte vorbehalten.
Keep away from sources of ignition Mantenha afastado de fontes
Kein Teil dieser Veröffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystem
- No smoking. de ignição - Proibido fumar. gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopiren, Aufzeichnen oder auf sonstige Art,
übertragen werden.
Conserver à l'écart de toute flamme ou
source d'étincelles - Ne pas fumer.

Geeignete Schutzhandschuhe tragen. Usare guanti adatti.

Ainda que se tenha lido o máximo cuidado na compilação da informação contida nesta publicação, a Delphi Diesel Systems Ltd., não pode aceitar qualquer
Aangepaste veiligheidshandschoenen responsabilidade legal por inexactidões. ADelphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento qe pode porventurau
Usen guantes adecuados. alterar as especificações do produto. ADelphi Diesel Systems Ltd. reserva o direito de alterar especificações sem aviso e sempre que seja necessario
dragen
para assegurar um desempeho óptimo da sua linha de produtos.
Todos os direitos reservados.
Wear suitable gloves. Use luvas apropriadas. Nenhuma parte desda publicação pode se reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por
quaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.

Porter des gants appropriés.

 4]
1 -2p02y
02 11o
/2 29-C
04 ]n- c[ e
VNa
iv
el d
ph
[D A

[Link]

Delphi Technologies | Wireless House, 1 Warwick Technology Park, Gallows Hill, Warwick, CV34 6DA, United Kingdom
Tel: +44 (0) 1926 470000 | Fax: +44 (0) 1926 472000

© BorgWarner Inc. Delphi Technologies is a Brand of BorgWarner Inc.