WORKSHOPMANUAL

COMMON INJECTOR (DFR1IA) P-REPAIR PROCEDURE

TM

2016
 INDEX

INTRODUCTION I

DIAGNOSIS II

DISMANTLING/ASSEMBLY III

APPENDICES IV

Edited and produced by:

Delphi France LLC
Diesel Aftermarket
12 - 14 Boulevard de l’industrie
41042 Blois Cedex Tel: (+33) (0) 2 54 55 39 39
France Fax: (+33) (0) 2 54 55 39 12
© Delphi Diesel Systems France

DDNX299(E) - Edition 1 of 03/2006 i

INTRODUCTION

INDEX
1.1

INTRODUCTION
........................1-1
1.2 RECOMMENDATIONS
IMPORTANT...
1.3 IDENTIFICATION OF
INJECTOR
ii DDNX299(E) - Edition 1 of 03/2006
 DIAGNOSIS
II

INDEX
2.1 VEHICLE SYMPTOMS AND DIAGNOSTICS
FAST........................................................................................2-3
2.2 DIAGNOSIS OF
BANK...............................................................2-6
2.2.1 Leak Test
static..............................................................................................................................2-6
2.2.2 Test of leaks
dynamics...........................................................................................................................2-6
2.2.3 Fuel supplies delays y of
opening
DDNX299(E) - Edition 1 of 03/2006 iii
 DISMANTLING/ASSEMBLY

INDEX

3. DISASSEMBLY
3.1 INTRODUCTION
.............................................3-9
3.1.1 Repair del
injector
.....................3-9
3.1.2 Breakdowns y substitution of
pieces
......3-9
3.1.3 Description of the
pieces
3-9
3.2 PREPARATION FOR THE
DISASSEMBLY
3-10
3.3 PLACEMENT DEL INJECTOR EN SU
SUPPORT.....................................................................................................3-10
3.4 LABEL
ID
............................3-11
3.5 PIECES
EXTERNALS.......................................................................................................................
..............................3-11
3.5.1 Sleeve external - Ford
Puma
....3-11
3.5.2 Capsule of
tobera
.........................3-12
3.6 PARTS
INTERNALS
.............................3-12

4. ASSEMBLY
4.1 WORK
PRELIMINARY
.........................4-15
4.2 SPARE PARTS
............................................4-16
4.2.1 Table of
breakdowns
.............................4-16 4.2.2 Procedure of
substitution
..............4-17
4.2.3 Notice before the
assembly............................................................................................................................4-17
4.3 ASSEMBLY DEL
INJECTOR
.................4-18
4.3.1 Dock y fastener of
calibration
.........4-18
4.3.2 Others components
internos
...........4-19
4.3.3 Components
externals
.....................4-20
4.4 CHECKS TRANSACTION THE
REPARACIONES....................................................................................................4-21
4.5 VALIDATION DE LA
REPAIR
.........4-22
4.6 TRACEABILITY
............................................4-22
4.7 EQUIPMENT
NECESSARY
...........................4-22 4.8 MAINTENANCE DE The DEVICES DE
MEASURE.........................................................................................4-23

iv DDNX299(E) - Edition 1 of 03/2006

 APPENDICES
IV

INDEX
5.1 Appendix I "Butchering of
injector............................................................................................................................5-25 5.2
Appendix II "Summary of the procedure of
repair
DDNX299(E) - Edition 1 of 03/2006 v
1.1 INTRODUCTION
To properly repair a Common Rail injector in terms of quality and cleanliness, they must
comply with the recommendations and methods described in the related documentation and must
Use the tools described in the appendix of this manual. Necessary equipment:
- A washing station.
- A bench with a metal coating, used only for working with injectors.
- A bench with soft metal clamps.
- Lint-free garments.
- Careclean cleaning product.
- A multidirectional pump support Hydraclamp.
- Plastic tray with different compartments to store the internal components of the
injector.
- Disassembly and assembly tools. YDT440- A set of master injectors.
Powder-free latex gloves.

Attention! These master injectors must be checked regularly (at least once a
week) to detect any possible deviation from the test bench.
Parts for repair:
To ensure the proper functioning of the repaired injector, the components will be replaced.
defective with original parts; the list of parts shows their references.
Repair note:
A 'repair note' must be filled out for each repaired injector, with the
next information: - Injector reference.
- Serial number.
- Vehicle mileage.
- DTCs or symptoms noted during diagnosis. Parts substituted during the
repair.
- Summary of the results in the test bench (before and after the repair).

1.2 IMPORTANT RECOMMENDATIONS

When working on the injector, cleanliness and safety conditions must be met.
stipulated in the Common Rail "GENERIC" manual DDNX126.
A complete diagnosis of the injector will be carried out before disassembling internal or external parts.
It is strongly recommended to check the injector on the test bench to determine the
cause of the breakdown.
The injector components must be reassembled under extreme cleanliness conditions.
Residual dirt can damage the injectors after their installation.
- The reused parts will be washed and dried in advance. Before reassembling them, the
Parts will be lubricated with ISO 4113 lubricant.
- During assembly, the parts will be stored in a clean area without metal, fiber, or dirt.
of other types.
- All parts that are to be reused will be visually inspected regarding their
general state.
Only the recommended disassembly and assembly tools will be used.
by Delphi. The joints will be systematically replaced every time they
disassemble these pieces.

1-1
INTRODUCTION
Any part that shows signs of deterioration, corrosion, cracks or
deformation.

1.3 IDENTIFICATION OF THE INJECTOR

The CR injector is identified by:

• Your reference: Starting with the letters EJBR or EJDR.
Your serial number.
- The first 4 digits represent the order number for the injector body.
- 1 letter represents the production month: A for January, M for December. The
letter I.
- 1 letter represents the production year: U for 2001, V for 2002, etc.
- 2 letters represent the production day.
- 1 letter represents the place of production: W for La Rochelle and F for Blois.
- 1 or 2 digits represent the test line number.
 DIAGNOSIS
II
2.1 VEHICLE SYMPTOMS AND QUICK DIAGNOSTICS
Symptoms/Malfunctions
During the initial diagnosis, the following table can be used to determine the function
defective.
Symptoms observed in the vehicle Possible cause
Dirt in the valve
Corrosion of the valve
Needle stuck due to dirt, corrosion
Dirt in the internal holes
Filter clogged with dirt inside
Loss of performance, instability, noise,
smoke Defective coil, open circuit
Electrical connector failure
Broken injector nozzle
Broken valve spring
Intermittent fault: short circuit/circuit
open
Broken valve stem
Stuck open valve
Excessive engine regime Broken or damaged valve spring (corrosion)
Stuck open needle (corrosion, dirt)
painting
Partially blocked internal openings
dirt
Smoke, unstable idle Leaks in pressure surfaces
Wear on the needle/separator contact
Unstable electromagnetic force (failure)
Unstable idle (due to an irregular end) intermittent in the internal electrical connection
from the injection)
Spring failure (corrosion, fatigue)
Blocked internal orifices (dirt)

Loss of power, difficulty starting, Soot deposit

draft risk Corrosion
Painting
Broken needle dock (corrosion, force)
excessive
Difficulty starting Loose needle dock (fatigue due to
excessive temperatures or speeds
Excessive nozzle temperature
DDNX299(E) - Edition 1 of 03/2006 2-3
DIAGNOSIS

Symptoms observed in the vehicle Possible cause

Stuck open injector

Excessive engine regime (due to leak of Dirt under the needle seat
combustible through the tip of the injector Stuck open valve (dirt underneath the
between two consecutive injections valve seat
Painting

Power loss, instability, noise Filter blocked by dirt

due to faulty injection start Bobbin: open circuit
Engine stop Bobbin: Short Circuit
The first phase must be completed using the tests described below.
Before disassembling the injector:
1. Before working on the injector, the diagnostic procedure will be started with a
external verification. a. Injector status check:
- Excess of soot deposits.
- Damaged tip.
- Presence of closing washer.
- Status of the return connection. State of the M14 thread.
b. Locate possible leaks:
- Around the nut/body thread of the
injector. Around the return connection.
c. Recorded liquid level:
- Extremely low (or vapors).
- Contacts and external parts completely wet.
d. Type of liquid:
- Gasoline
eo.
- Oil
. -

Others.
External cleaning.
a. Seal the nozzle, the return connection, and the M14 thread on the injector body.
b. With a screwdriver, clean the slot between the nut of the nozzle and the nozzle.
c. Spray the nut and the tip of the injector with a degreaser. Notice, these products
They can damage the hands and eyes. The action takes more or less time depending on
of the chosen cleaning product.
d. Remove the nut and clean to eliminate the carbon deposits around the
injection orifices. Delphi recommends the use of ultrasonic cleaning to ensure
the sufficient cleaning before moving it to the test bench. The toberano must be brushed
since it can alter its operation.
e. Clean the entire injector with a concentrated cleaning product in the areas of
more risk Dry the injector.

Attention! It is essential to clean the nozzle, as the flow meter is extremely

sensitive to dirt.
2-4 DDNX299(E) - Edition 1 of 03/2006
 DIAGNOSIS
II

3. Electrical tests.
This test is carried out in two phases:
a. Checking the status of the coil.
Install the injector on the bench and measure the resistance of the coil.
At 20ºC, the resistance of the coil must be between 0.155 Ohms and
0.185 Ohms. The resistance must be greater than 10 megohms.
b. Checking of the valve movement.
Start the valve test. This is an automatic test that performs a number
default traveling cycles of the valve.

If the resistance of the coil is within tolerances and the movement of the
the valve is audible, the electrical part of the injector is operational.

Attention! The electrical test assumes that the connections, insulation, and continuity
Electrical in the control circuit of the bank is correct.

If the diagnosis shows a failure in the coil, reject the injector.

Attention! For all bank tests, you must first ensure that the liquid
of ISO 4113 test and the hydraulic circuits (all the HP hoses and the rail) are
completely clean. We highly recommend cleaning the circuits for
ensure that all dirt (metallic, organic, or other) is removed. In particular,
Make sure that the 2 µm filter is replaced regularly. Failure to comply with these
Recommendations may damage the tested injectors.

In a similar way, before placing an injector on the test bench, you must
decarbonize in an ultrasonic bath.
4. Leak test.
Consult section 2.2.
5. Functional test on the test bench.
Consultar la sección 2.2.
DDNX299(E) - Edition 1 of 03/2006 2-5
IIDIAGNOSIS

2.2 BANK DIAGNOSTIC

2.2.1 Static leak test

In this phase, it must be ensured that the injector has no leaks in static mode:

1. Mount the support spacer for the injector on the bench. This part helps to
detect and recover leaks from the nozzle. 9378
2. Install the injector on the test bench once all have been taken
cleaning precautions.
3. Tighten the HP tube to a torque of 25N on the rail side, following the injector side.
4. Connect the injector tube to the return flow meter.

Attention! Do not connect the electrical components of the injector.

5. Start the static leak test through OCRES
6. Check for static leaks from the nozzle (injected flow) and from the slot between
the nut and the body of the injector.
7. Measure the flow of static leaks (return).
- Static return above the maximum limit (fixed in OCRES) or leakage appearance
around the toberao around the slot of the body of the support of the
nut/nozzle, the injector has leaks. The unit must be disassembled to
diagnose a malfunction in the internal parts.
- Static return below the maximum limit (fixed in OCRES) or without leaks around
from the nozzle or around the slot, the injector has no leaks. In this case,
carry out a dynamic leak test.

2.2.2 Dynamic leak test

The dynamic leak test consists of measuring the return from the injector under
specific operating conditions. The unit will be controlled regarding the
reproduction of the pre-calibrated injections in OCRES. To ensure this, remove the
separator used previously and replace it with a separator without a side hole. Before
To start the flow measurements, the following conditions must be met: - Generate a
minimum temperature of 40°C for the test liquid (ISO 4113).
 - Cleaning and temperature adjustment of the injector.
- Start the dynamic leak test through OCRES
Measure the return, if the flow exceeds the maximum limit (fixed in the test program of
OCRES), the injector is defective (valve wear).

2-6 DDNX299(E) - Edition 1 of 03/2006

 DIAGNOSIS
II

2.2.3 Fuel supplies and opening delays

If the tested injector has no leaks, measure the injected flows and the opening delays.
for the five pressures mentioned below.

Attention! To ensure accurate measurements, test only ONE injector at a time.

The activation of the supply unit of measure may affect the measurements of
opening delay. Consequently, this unit must be deactivated when measuring the
opening delay.

During this phase, simply launch the 'Diagnostics' program in OCRES. The
Fuel supply will be measured for each pressure in the rail [230, 400, 800, 1200, 1600]
bar] and for different impulse lengths between 0 and 1600 µs (mm3/stroke). The delay of
opening is measured at 800, 1200, and 1600 bar. The obtained results are compared with the
reference data for the injector in question.
If the curves for flow and opening delay are within tolerances, remove and
seal the injector. The recommended cleaning instructions by Delphi must be followed.
in the entire operation.
If the measured characteristics for this injector are outside of the tolerances, remove the
test bench injector, and disassemble the injector and replace the defective parts;
make sure to comply with the related cleaning and safety instructions.
DDNX299(E) - Edition 1 of 03/2006 2-7
 DISASSEMBLY/ASSEMBLY
III

DISMANTLING
3 DISMANTLING

3.1 INTRODUCTION

3.1.1 Injector Repair

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

3.1.2 Breakdowns and replacement of parts

The following table summarizes the most common faults detected in the test bench and the
parts that will be replaced in each case.
Parts to be replaced
Conjunction Past Body
Conjun Dock Travel
to de r of of
Type of Nut to de of Separated tea of
valve calibrate injector/
breakdown a needle injection or valve
/ action coil/you
body r a
seat bo
Resistance Reject the injector
a:
No hay If the resistance is correct,
vibration see below:
is from the x x x x
valve
Escape
static X X
return
Escape
static X X X
nozzle
Escape X X X X X X
dynamic
Combustible X X X X X X
the pilot
Fuel
the X X X X X X
principal
Delay
of X X X
opening
 This table is provided only as a reference, as it is impossible to display all the
replacement options for the parts, according to the different types of breakdowns of
the injectors. In fact:
- The wear on a part can result in different modes of failure in the
injector.
- A failure in the injector may be caused by a combination of several types.
of breakdowns. To increase the reliability of the repair, all parts subjected to
wear will be replaced each time the injector (valve, seat) is disassembled
valve, nozzle assembly, springs.

3.1.3 Description of the parts

Consult Appendix I of this document.

DDNX299(E) - Edition 1 of 03/2006 3-9

DISASSEMBLY/ASSEMBLY

DISMANTLING
3.2 PREPARATION FOR DISASSEMBLY
The injector will not be disassembled in the area reserved for assembly.
Use disposable latex gloves when working on the injector.
In this phase, it is assumed that the injector is externally clean (decarbonization and cleaning).
- Remove the closing washer with a pair of
universal pliers. 9335
- Citroën injector: Remove the retaining ring
external with the pliers provided
with the kit.
YDT440

3.3 INSTALLATION OF THE INJECTOR ON ITS SUPPORT

Install the injector in the main support and

hold it in its position.
To avoid damage to the nozzle, place the intake.
in the nut so that the injector rotates in the
fastening device.
3-10 DDNX299(E) - Edition 1 of 03/2006
 DISASSEMBLY/ASSEMBLY
III

DISASSEMBLY
3.4 LABEL ID

Use the tool YDT441 to remove the

injector label. See opposite figure.
9368

Attention! After removing the label, clean the

application area. Remove all remnants of the
adhesive or other materials. The quality of the
Surface determines the effectiveness of the adhesive.
on the new label.

3.5 EXTERNAL PARTS

3.5.1 External sleeve - Ford Puma To disassemble this injector, disassemble first
place the external nut (sleeve nut). To do this, mount the two sleeves on the
main fastening device YDT437.
Insert the injector and secure the cutter
tubes in the fastening device
main, so that the knurling
I was situated as shown in the
opposite figure (in the center of the area
indicated).9338
Slowly tighten the nut: for two
start turns, turn the knurling in
the pipe cutter a quarter turn.

Attention! The non-compliance

from these recommendations you can
damage the knurling and the rollers.

Remove the nut and the internal elastic ring.

DDNX299(E) - Edition 1 of 03/2006 3-11
Dismantling/Assembly

DISMANTLING
3.5.2 Nozzle Capsule
Before releasing the nozzle capsule,
first place, relieve the forces of the
injector to prevent the pins
internos se corten. Para ello, realizar una
slot in the nut using the cutter 30 mm
of tubes. The slot must be placed at 30
the edge of the nut and the
depth will be less than 0.5 mm.
9351

Attention! Do not cut the nuts, as

it can make disassembly difficult.

- Partially loosen the capsule of the

tobera.
- Remove the injector from the fixture
principal.9349

3.6 INTERNAL PARTS

Loosen the nut manually.

Attention! Be careful not to drop

the internal parts (needles, springs,
separator, valve, etc.)

When the injector has been disassembled,

separate the internal parts in a tray
disassembly. 9357
3-12 DDNX299(E) - Edition 1 of 03/2006
 DISASSEMBLY/ASSEMBLY
III

DISASSEMBLY
- Remove the calibration pin located at the base of the injector body housing.
9360

- Introduce the injector body into the

cleaning support YDT439.9361

Attention! Cover the holes HP first

to start the brushing operation. If
dirt is introduced into these channels,
it can damage the injector.
- Brush the injector threads with a
metal brush.
If necessary, finalize the cleaning of the
powdering cookies a
degreaser (Decapping
LOCTITE 7200

Attention! This product may cause damage

the hands and the eyes. Be careful when using it.
- Clean the threads with a blow gun.
The cleaning will remove everything
remains of metal dirt, grease or
resin of the threads.
DDNX299(E) - Edition 1 of 03/2006 3-13
 DISASSEMBLY/ASSEMBLY
III

ASSEMBLY
4 ASSEMBLY

4.1 PRELIMINARY WORK

The injector repairs consist of replacing the defective parts with original ones.
effective repairs depend on the quality of the diagnosis made previously and the
compliance with the method used to reassemble the new parts.
Once disassembled, visually check the condition of the following internal parts to
check the source of the failure:
- Needle.
- Nozzle body.
- Needle dock.
- Valve and valve body.
- Adapter plate.
- Injector body.
- Valve spring.
- Calibration pass-through.

Note: In this phase, it is assumed that the electrical parts are functioning completely.
the coil must be disassembled.

Check for contamination from organic or metallic sources to locate the cause of the
breakdown.
Wash and dry the reusable internal mechanical parts. Then, check for any
scratches, dents, wear, deformation and corrosion.
Any piece that shows signs of damage will be replaced with a new one.

Attention! We recommend moving the pieces carefully to avoid scratches or

deformation.

Any piece that falls will be automatically rejected.

DDNX299(E) - Edition 1 from 03/2006 4-15
DISASSEMBLY/ASSEMBLY

ASSEMBLY
4.2SPARE PARTS

4.2.1 Breakdown Table

The table below provides detailed information on the breakdowns that need to be checked in
the pieces.
Set Piece Breakdowns
Nozzle assembly Needle Particles in slots of
nutrition
Resaltesy/o rebabas in the
feeding slots
Scratches
Damage to the cone of the
needle
Rebates and/or deformation of
the base of the needle, side of the
separator
Remnants of corrosion
Remnants of strangulation
Nozzle body Resalts
Remnants of leaks
Scratches on the surfaces
of pressure
Corrosion on the surfaces
of pressure
Cracks around the opening
HP
Presence of particles and/or
shavings
Scratches on the diameter
Injection orifices
blocked
Needle dock Presence of particles in
the coils
Broken dock
Valve Valve body Surface of pressure
Restos de fugas y rayaduras
on the surface of the 'body',
corrosion on the surface of
the 'adapter plate'.
Seat: Remnants of leaks,
scratches, corrosion
 Pollution of the HP canal
Valve stem Particles in the stem
Support cone: scratches,
residues, waste from leaks
Adapter plate Surface of pressure
Remnants of leaks and scratches
on the surface of the
'tobera', corrosion in the
surface of the 'valve'.
Pollution of the HP canal
4-16 DDNX299(E) - Edition 1 of 03/2006
 DISMANTLING/ASSEMBLY
III

ASSEMBLY
Set Piece Breakdowns
Injector body. Body Surface of pressure
Remnants of leaks, deposits,
corrosion scratches
Resaltes
HP and/or contamination
return channels
Dock Presence of particles in
the coils
Broken dock

4.2.2 Replacement procedure

Consult section 3.1.2 for internal parts.
Note: Due to the dismantling procedure damaging the nozzle capsule, it must
automatically replace itself.
Similarly, the sealing washer and the elastic ring must be replaced (according to
the injector) for new parts.

4.2.3 Notice before assembly

The following cleaning guidelines will be fulfilled before and during the assembly of the injector:
Cleaning
All reusable parts will be washed in advance. The mechanical parts go through
automatically to the washing station. Special attention must be paid to the remnants of
thread adhesive (use a degreaser on the bench grinder, if necessary)
and check the condition of the threads at the end of the operation). The threads of the body of
Injectors must be completely clean.
Drying
Dry all washed pieces to avoid any residual dirt. A can be used.
blowgun to eliminate any remaining dirt.

Attention! Be careful not to push dirt into the inside of the parts or the channels.
HP

Storage
The injector parts must move and be stored in a pressurized environment while
they are waiting for the assembly.
DDNX299(E) - Edition 1 of 03/2006 4-17
DISASSEMBLY/ASSEMBLY

ASSEMBLY
4.3 INJECTOR ASSEMBLY
- The conditions must be met
previously mentioned cleaning
during the assembly.
- The moving parts will be lubricated before the
assembly.

In this phase, it is assumed that the injector that is

it is being repaired, there are no electrical breakdowns.

Before starting the assembly, check the

coil position. 9373

4.3.1 Calibration spring and pin

The spring and the body pin of the
injector for repair, they are bonded
to ensure accurate calibration. L
They must not be separated.4312They will return to
assemble the same paired pieces
Fastener of
to meet the calibration of 18 +/-0.7 N
about 22 +/-1 N depending on the calibration
injectors, where L = 40 µm. If not
does not meet this criterion, it cannot be
to ensure the proper functioning of the
injector.
If it is disassembled in advance, insert the
calibration spacer in the housing
of the provided injector body.
If the slider es
CPI
staggered, the large opening will be placed
outward (side of the dock).

Attention! There are 19 types of fasteners. They are not interchangeable.

The dock (washed, dry and free of dirt) must

insert yourself in the accommodation in front of the pin.

Attention! There are several types of

springs. They are not interchangeable.
4-18 DDNX299(E) - Edition 1 of 03/2006
 DISASSEMBLY/ASSEMBLY
III

ASSEMBLY
4.3.2 Other internal components
- Deposit a minimum of 15 mg of
Mobilith grease 220SHC
extended in a way
uniform on one of the surfaces
from the contact of the capsule/nozzle.
- Stack the internal parts
y manually tighten the
nut for guarantee what
remain in position.
- Assemble the set about the
main fastening device. The
contact points are:
M14 nut
the conical area of the nozzle.
- Tighten the bracket screw
Apply a force of 40 N to compress the internal parts against each other.
In this way, it prevents the entry of
dirt on these components.
- Manually loosen the nozzle capsule.
- In the area between 2.5 and 5 mm from the surface of the injector body sight glass,
introduce two drops of LOCTITE 222 adhesive into the threads of the body at 180°. 9343

The polymerization time for the adhesive is 10 minutes.

Attention! The nut and the threads of the body will not have grease or dirt.

- Next, press according to the guidelines

For a maximum of
opposites. Vehicle
Pair of
preparatory
Angle of inspection
(N m) tighten (º) (N m)

Renault 20 +/- 0.2 45 +/- 3 60

Ford Lynx 20 +/- 0.2 45 +/- 3 60

Ford Puma 20 +/- 0.2 35 +/- 3 55

Kia 20 +/- 0.2 45 +/- 3 60

Citroën 20 +/- 0.2 41 +/- 3 55

SsangYong 20 +/- 0.2 45 +/- 3 60

DDNX299(E) - Edition 1 of 03/2006 4-19
DISMANTLING/ASSEMBLY

MONTAGE
4.3.3 External components
Spherical washer and elastic ring
Use the pliers YDT443
supplied with the kit of
tools to place the ring
elastic.9367

Assembly of the body socket

injector This nut is mounted on the
injector through the end of the
injector nozzle:

- Check that the outer sleeve

it incorporates its elastic ring. In case
on the contrary, use the casing YDT444
for the assembly. Introduce
manually the elastic ring in the
nut9363and finish pushing it
in your accommodation with the sleeve
YDT444.9365

- Protect the injector with caps

appropriate plastics.9369
- Place the tool YDT447 in a
bank.
- Place the injector in a tool YDT447 and protect the tip of the injector with a
metal cap 9370YDT445.

4-20 DDNX299(E) - Edition 1 of 03/2006

 DISASSEMBLY/ASSEMBLY
III

MOUNTING
Place the external sleeve with the ring
elastic in its position. 9371-1
With a tool YDT446 and a
a lot, introduce the nut in the
injector.

4.4 CHECKS AFTER REPAIRS

Strict tests must be carried out on each repaired injector. The component will comply with the
the following functional requirements:
- Coil resistance within tolerances.
- External sealing.
- Internal sealing.
- Fuel supplies within tolerances.

When these criteria are checked, follow these instructions:

Resistance of the coil
A = 20°C 0.155 Ohm < R < 0.185 Ohm
Insulation resistance > 10 M Ohm

External and internal leak testing

Consult section 2.2.

Fuel supply and fuel injector calibration

No correction code is entered into the control system for operations.
next. The injector must be characterized first without any correction.
- Install the injector on the bench while adhering to the necessary cleaning and guidelines
Press. - Select the type of injector to be tested.
- Start the tests for each pressure level.
- Measure the following parameters:
Opening delay. Consult section 2.2.
=> Fuel supply. Consult the
section 2.2. Generate the correction code.
The hexadecimal code is generated by comparing the results for the tested injector and the curve.
Reference curves are generated on the test bench using injectors.
new ones with the same reference as the repaired injector.
This operation is carried out before calibrating the repaired injector.

DDNX299(E) - Edition 1 of 03/2006 4-21

DISASSEMBLY/ASSEMBLY

MOUNTING
4.5 VALIDATION OF THE REPAIR

Once the injector corrections are generated, repeat a full test after
introduce this new code in OCRES. The flow values obtained during this final test
must correspond to those of the reference injector within the predefined tolerances.
If the mentioned operational criteria are met, package and store the component in an environment
clean while waiting for the vehicle assembly. If this is not the case, repeat the diagnosis and the
repair procedure.
Once the injector is repaired, install the corresponding spark protector washer.
Consult the list of parts for the washer references.

4.6 TRACEABILITY

Print the new correction code.

Use the printer and the type of label recommended by Delphi.
The ID label contains the following information:
- Injector reference.
- Injector serial number.
- Correction code calculated in the test.
- Delphi distributor ID that carried out the repair. Repair date.

For certain applications, it may be necessary to print two different labels: One with the code
for correction and the other with the remaining information.
In all cases, we strongly recommend the separation of information: The codes
Corrections generated during the test will also be recorded in the repair notes.
sent to the client and stored in the vehicle. Each code must be linked to a number of
series for the affected injector and the number of the cylinder for which it is placed.

4.7 NECESSARY EQUIPMENT

- Ultrasonic cleaning station: External cleaning of the faulty injector and washing of the parts
reusable internals.
- Clean the overpressurized cabinet for handling clean internal parts.
- Test bench with testing equipment for the CR injector and OCRES testing software
DDRX101. Amplification system (30 times) to detect possible dirt.
- Dismantle and reassemble the kit for the Common Rail Injector YDT440. Printer
of labels and its software: DYMOLabelManager PC.
- Consumibles:
Mobilith 220SHC Grease.
LOCTITE 222 adhesive.
Liquid of washing
ultrasonic. Roll of
tags.
Attention! It is important to use the label roll adapted to the environment of
motor and compatible with the mentioned DYMO printer. Recommended products: Rollo
D1 permanent white polyester with a width of 12 mm (DYMO Reference:
16959) and a width of 19 mm (DYMO Reference: 16960).

4-22 DDNX299(E) - Edition 1 from 03/2006

 DISMANTLING/ASSEMBLY
III

ASSEMBLY
4.8 MAINTENANCE OF MEASURING DEVICES
The accuracy of the measurements taken on the test bench depends on numerous factors:
- The configuration of the test bench. Any modification during assembly or the
The addition of a component must be validated by Delphi.
- The test temperatures. They must comply with the liquid cooling recommendations.
to avoid any deviation associated with temperature.
- The quality of the test liquid. The commands of high temperature and high pressure can
damage the quality of this liquid. Therefore, this parameter must be controlled
carefully and replace the liquid regularly.. It is reminded that this liquid must
comply with the ISO 4113 standard and have a viscosity between 2.45 and 2.75 cSt at 40°C. In addition, the
replacement interval of the 2 µm filter must be met to prevent penetration of
dirt in the injectors during the test.
It is reminded that the reliability of the measurements depends on the fulfillment of the conditions of
Testing and the conditions of the test equipment. Therefore, it is essential the
Verification that the bank measures correctly. To do this, test the master injectors.
(measure the flows and opening delays) at least once a week.
DDNX299(E) - Edition 1 of 03/2006 4-23
IVAPPENDICES

5.2 Appendix II "Summary of the repair procedure"

No. Steps Rejected parts New parts and
consumables
1 Release the locking washer Washer
2 External visual inspection Complete injector if there is
(scratches, dents, leaks) notches M14, in the tube or
injector body.
3 External washing
4 Bank diagnosis (electrical and
hydraulic
5 PI Ford Puma: Remove the sleeve Outer shell
external
6 Remove the label C21/C31 C2I/C3I label
7 Remove the lid Nut
8 Dismantle the injector Depending on the type of
repair
Valve set
Set of the nozzle
keeper, valve spring
Nozzle dock
9 Visual inspection of non-pieces
rejected
10 Brush the threads of the body of the
injector
11 Wash all reusable parts
12 Check the pressure surface
of the support body of the
nozzle
13 Check the position of the
coil.
14 Introduce the calibration pin Pin and spring
(if it has been replaced) and the spring of (if so
the valve replace
15 Lubricate the nut Fat
16 Mount the pieces internal Internal parts
(injector set, valve, cambiadas
separator, springs
17 Compress the set of the
internal parts
18 Deposit adhesive on the threads Adhesive
19 Tighten the nut and tighten to the torque and
the recommended angle
20 Mount the outer sleeve (PI External nut and
Puma elastic ring ring
(PI Citroën) elastic
21 Bank tests: electrical leaks,
static and dynamic
22 Properties of the injector
23 Generate the correction code
24 Place the closing washer Closing washer
25 Print and apply the label Label
5-26 DDNX299(E) - Edition 1 of 03/2006
 APPENDICES
IV

No. Steps Rejected parts New parts and

consumables
26 Cover and pack Toppings of
protection, bag
and packaging.
DDNX299(E) - Edition 1 of 03/2006 5-27
Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any
inaccuracies. Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel
Systems Ltd. reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its product range. 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, recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.

Special attention has been given to ensure the accuracy of the information contained in this publication by Delphi Diesel Systems Ltd.
but the company declines all legal responsibility in this regard. Delphi Diesel Systems Ltd. is pursuing an intensive design program of
development that may lead to changes in product specifications. Delphi Diesel Systems Ltd. reserves the right to modify the
specifications, without notice and if necessary, to ensure the optimal performance of its product range. All rights reserved
Any reproduction, storage in a computer system, or transmission in any form whatsoever, or by any electronic means,
Mechanics, by photocopy, recording or otherwise of this publication is prohibited without the prior permission of Delphi Diesel Systems Ltd.

Even though every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. disclaims any liability for
possible inaccuracies. Delphi Diesel Systems Ltd. carries out an intensive design and development program that may change the specifications of
product. Delphi Diesel Systems Ltd. reserves the right to modify the specifications without notice and whenever it deems necessary to ensure the
optimal performance from its range of products.
All rights reserved
No part of this publication may be reproduced, stored in an electronic system, or transmitted in any form or by any means,
electronic, photocopying, recording or otherwise, without prior permission from Delphi Diesel Systems Ltd.

Although we have taken all necessary precautions in compiling this publication, Delphi Diesel Systems Ltd. accepts no responsibility.
Legal for inaccuracies that may appear in it. At Delphi Diesel Systems Ltd., an intensive design and research program is being followed which
may alter the product specifications at any time. Delphi Diesel Systems Ltd. reserves the right to alter the specifications.
without prior notice and whenever necessary to ensure the best possible functioning of their products. All Rights Reserved
It is not allowed to copy, store in a retrievable system, or transmit this publication in any form or electronic, mechanical, photocopy method.
recording or any other, without prior authorization from Delphi Diesel Systems Ltd.

The information contained in this publication has been compiled with the utmost care. Delphi Diesel
However, Systems Ltd. cannot be held legally liable for any inaccuracies. Delphi Diesel Systems Ltd. carries out a
forlaufendes Design und Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produkdaten ändern. Delphi Diesel Systems Ltd. behält sich das
To change specifications at any time without prior notice in order to ensure the optimal performance of its products.
All rights reserved.
No part of this publication may be reproduced without prior permission from Delphi Diesel Systems Ltd., in a data processing system.
stored or in any other manner, whether electronically or mechanically, by photocopying, recording or otherwise
Art, to be transmitted.

Although the utmost care has been taken in compiling the information contained in this publication, Delphi Diesel Systems Ltd. cannot accept
any legal liability for inaccuracies. Delphi Diesel Systems Ltd. has an intensive design and development program that can
may change the product specifications. Delphi Diesel Systems Ltd. reserves the right to change specifications without notice and whenever it is necessary.
necessary to ensure optimal performance of your product line.
All rights reserved.
No part of this publication may be reproduced, stored in a system from which it can be retrieved, or transmitted in any form, or by
by any means, electronic, mechanical, photocopying, recording or others, without prior permission from Delphi Diesel Systems Ltd.