Technical Documentation for Customer

Document Identification / Version: V10

Product Designation:

GDI injector

Application:

RENAULT H5FT

Part Number:
Loop
Supplier choice (R2b spray)
preB2 (R2b spray)
B2 (R2b spray)
B2 (R2c spray)
IOD (R2c spray)
M/P [rank 1 Qmin]
M/P [rank 2 Qmin]

RSA part number

166002091R
166004327R
166008489R
166004395R
166004350R
166002033R
166006130R

PLH

PLH 8201141604

Version
V10

DENSO part number

5-298500-009
5-298500-012
5-298500-038
5-298500-135
298500-0060
298500-0060
298500-0060

Comment
Official release to customer from IOD loop

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Release Date
22nd Sept 2010

Technical Documentation for Customer

Document Identification / Version: V10

TABLE OF CONTENTS
1. GENERAL PRESENTATION .................................................................................................................................. 3

2. COMPONENT OVERVIEW .................................................................................................................................... 4

3. TECHNICAL SPECIFICATIONS .............................................................................................................................. 5

4. MOUNTING SPECIFICATIONS ............................................................................................................................ 16

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Technical Documentation for Customer

Document Identification / Version: V10

1. GENERAL PRESENTATION
The GDI injector is used to inject fuel into the combustion chamber with:
- Adequate timing
- Adequate quantity
DENSO GDI injector is multi-holes injector (6 holes). Below is presented injector detailed shape for IODloop

2.69mm
3.05mm

*
*
*

*
*
*

* Change portions due to tolerance ring change from B2loop to IOD loop (DENSO M/P standard design)

NOTE:
For monocylinder/ preB2 and B2 loop engines, thickness of tolerance ring is thinner by 0.36mm as temporally
solution. DENSO requests to go back to standard tolerance ring height for IOD and M/P part (See picture above).

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Technical Documentation for Customer

Document Identification / Version: V10

2. COMPONENT OVERVIEW
Injector component materials are chosen to have flex fuel capability up to E85.

No

Parts

Materials

1
2
3
4
5
6
7
8
9
10

Insul. Injector, Lower

Holder, Valve
Washer, Slider
Housing, Lower
Holder, Injector
Mold, Connector
Seal, Oring
Seal, Oring
Ring, Stopper
C-ring

PTFE
SUS405
SUS430
SUS405
SK5
PA66G
PTFE
FKM with Grade for Low Temperature
PPS
SUS304

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Technical Documentation for Customer

Document Identification / Version: V10

3. TECHNICAL SPECIFICATIONS
3.1. GENERAL DESCRIPTION
Number of holes
Electrical connector
Electrical connector counterpart reference
Electrical connector counterpart cable cross section
Weight
Fuel resistance
Filter characteristics
O-ring material (fuel rail connection)

6 (See Figure1 for spray coordinates)

Sumitomo 090 II
Sumitomo 6189-0566
1.25mm
80g
Standard gasoline EN228, E15, E85, M12
Mesh size : 40um
Filtration area : 18mm2
Rubber FKM (Fluoroelastomer) with GLT grade
(Grade for Low Temperature )

Figure 1 : Spray coordinates

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Technical Documentation for Customer

Document Identification / Version: V10

3.2. MECHANICAL SPECIFICATIONS

Max fuel pressure (Actual RSA spec)

15MPa

Max acceptable fuel pressure

20MPa
DENSO recommendation: 4 to 5MPa

Pressure for starting

Minimum operating pressure
Burst pressure
Static flow rate
Dynamic flow
Minimum fuel flow
Maximum seat leakage
Maximum seat leakage after ageing
Maximum external leakage
Static flow rate tolerance (New part)
Static flow rate tolerance (Aged part)
Dynamic flow tolerance (New part)
Dynamic flow deviation (Aged part)
Min fuel flow tolerance (RSA spec)
Min fuel flow tolerance (DENSO proposal)
Atomization
Maximum vibration level
Maximum Noise

Feed pressure
(Needle valve can be actuated at 0MPa)
27MPa
3
71221.4 cm /min @10MPa,Drysolvent
(REF: 739 cm3/min @10MPa,Gasoline)
(REF: 554g/min@10MPa with =750 kg/m3 (Gasoline))
8.17mm3/str@4MPa,Ti=0.95ms,Drysolvent
5.75mm3/str@4MPa,Ti=0.61ms,Drysolvent
(REF:5.93mm3/str@4MPa,Ti=0.61ms,Gasoline )
1.0mm3/min@8MPa, Drysolvent, 20C
Seat leakage is improved by ageing
0cc/min@15MPa
(besides O-ring seal part)
+/-3%
+/-3%
+/-3%
-3%/+4%
@ 0.6billion times actuating the injector
+/-3%
+/-3% achieved by classification of injector into 2 batches
(qmin rank1:5.75+/-0.17mm3/str
qmin rank2:5.41+/-0.17mm3/str
@4MPa,Ti=0.61ms,Drysolvent)
<15um @ 50mm/15MPa below nozzle tip
30G (for X, Y, Z axis)
70dB @ DENSO measurement method

3.2.1. DYNAMIC FLOW RATE ACCURACY (PART TO PART DEVIATION)

Flow Torelance (%)

[R eference] Theoreticaldynam ic flow tolerance

10
5
0
-5
-10
0.0

0.5

1.0

1.5

2.0
2.5
3.0
P ulse w idth (m s)

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3.5

4.0

4.5

5.0

Technical Documentation for Customer

Document Identification / Version: V10

3.2.2. FLOW RATE TEST METHOD

Test Conditions

Setup of the test

>Test Fluid Drysolvent (Specified Test Fluid)

>Fluid Temp. 20
Static flow
>Fuel Pressure 10MPa,
Dynamic flow ( adjustment point )
>Pulse width
1.1ms
>Drive voltage 14V

PC
Test Fluid

Pressure
regulator

Pressure
sensor
Fluid Container

Flow Mater
Injector

3.2.3. SHOT TO SHOT REPEATABILIITY

Tests conditions:
- Injector spec: B2loop
- Fuel: Drysolvent
- Fuel temp.: Room temp.
- Ambient temp.: Room temp.
- Driver: DENSO driver
- Number of injection: 500shot
- Peak current: 8.5A@4,10MPa, 9.0A@15MPa
- Supply voltage: 14V
-

CONCLUSION:
- Shot to shot repeatability became worse below the bending point.
- For special cases discussed with RSA (Re-atteling), pulse width down to the bending point can be used
- However, using the pulse width less than bending point cannot be recommended under any condition

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Technical Documentation for Customer

Document Identification / Version: V10

3.2.4. FUEL LEAKAGE TEST METHOD

Test Conditions
A ir bubble
CCD
displacem ent cam era
controlfilm
Thin glass
Silicon
tube(
tube(0.56)
oil
Sam ple

>Test Fluid Drysolvent (Specified Test Fluid)

>Fuel Pressure 10MPa
>Fluid Temp. 20
Fuel

A ir bubble
Illum ination

3.2.5. SPRAY ATOMIZATION TEST METHOD

Test Conditions

Setup of the test

>Test Fluid n-hepten

>Fuel Pressure
:15MPa
>Fluid Temp. 20
>Measurement position
: 50mm below nozzle tip

PDA:Phase Doppler Analyzer

<Measuring equipment>

3.2.6. REFERENCE FOR TEST SETUP OF SPRAY ANALYSIS

Analysis System of Spray Shape

Analysis System of Spray Structure

High Pressure Chamber

Spray analysis by Laser Sheet

Fuel
INJ

Stroboscopic
Lamp

Chamber
CCD Image Sensor

Sheet

Laser
Computer

Sheet

Laser

Chamber
CCD image sensor

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computer

Technical Documentation for Customer

Document Identification / Version: V10
3.2.7. NOISE TEST METHOD

Test conditions

Setup of the test

12
10

Acoustic chamber

Fuel rail

> Fuel : Drysolvent

> Fuel pressure : 4MPa
> Pulse width : 1.45ms
> Injection periodicity: 180ms
> Drive voltage : 14V
> Peak Drive current : bellow figure

400mm

Microphone

Competitor

Noise record timing

DENSO

Injection pulse

Valve open

Valve close

Needle lift

0
-2
- 0.5 0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Noise data
Duration of FFT analysis

10ms

3.2.8. NOISE MEASUREMENT RESULT

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10ms

Technical Documentation for Customer

Document Identification / Version: V10

3.3. Thermal Specifications

Maximum recommended nozzle tip temperature
Maximum acceptable nozzle tip temperature

DENSO recommends < 160C

(Robustness against injector tip deposit)
Material durable up to 250C
[-40C; +135C]
(If T>120C, DENSO cannot guarantee
injector performance)
[-40C; +120C]
(If T>80C, DENSO cannot guarantee
injector performance)

Acceptable ambient temperature range

Acceptable fuel temperature range

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Technical Documentation for Customer

Document Identification / Version: V10

3.4. ELECTRICAL SPECIFICATIONS

3.4.1. CURRENT/ VOLTAGE PROFILES

Current

Iboost
Ipickup
Hysteresis I hold

Ihold
T1

Voltage

Uboost

Time

T2

Tpickup

UBatt

Time

Tboost

Uclamp

Fuel
pressure

Uboost

Uclamp
(RSA
request)

Iboost

Ipickup

Upickup

Tboost

Tpickup

Ihold
(lower
level)

T1

0 - 12 MPa

8.5A

5.0A

Ubatt

440us

600us

DENSO has
no
requirement
for T1 value.

12 18.5MPa

9.0A

8.0A

Ubatt

460us

1100us

For reference,
T1=0.05msec
from 8.5A to
5A. (DENSO
nominal test
result using
DENSO
driver circuit)

65V

-65V

> 18.5MPa
= limp
mode only

2.1A

12.0A

Tolerance
(recommendation value)

8.0A

Ubatt

530us

1100us

T2

Energy

DENSO has
no
requirement
for T2 value.

135mJ

For
reference,
T2 is around
0.3msec
(DENSO
nominal test
result using
DENSO
driver
circuit)

Iboost

Ipickup

Ihold

+/- 0.5A

+/- 10%

Lower level: 2.1A

Hysteresis (Peak to Peak) : 0.7A

Ipickup depends on temperature and battery voltage.

DENSO requirement for pick-up phase:
1) Apply Battery voltage (MUST Item)
2) Adjust PWM to reach Ipickup value recommended by DENSO
3) In case, Ipickup recommended value cannot be reached due to battery and/or impedance value,
set PWM to 100%.
4) Keep Tpickup (MUST item) as recommended by DENSO to guarantee needle adequate opening

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148mJ

210mJ

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Document Identification / Version: V10
3.4.2. ELECTRICAL CHARACTERISTICS

1.44/ 1.89/ 2.7

1.8mH
Depends on DC-DC converter/ 14V/ 16V
See chart below

Coil resistance (@-30/ 20C/ 120C)

Coil inductance (@20C)
Operating voltage (Min/Nom/Max)
Minimum time between 2 consecutive injections

3.4.3. NEEDLE OPENING/ CLOSING TIME

Datas below come from measurements done on B2loop nominal static flow samples (16 parts).
However, this is not a commitment from DENSO, these values are for reference only.
Tests have been done with DENSO driver (9.7A) and drysolvent (20C).
< Reference>
Needle opening time [To]
Needle closing time [Tc]

Fuel Pressure
Average
3 dispersion
Average
3 dispersion

4MPa

10MPa

15MPa

20MPa

0.68ms
0.10ms
0.70ms
0.10ms

0.74 ms
0.10ms
0.66ms
0.10ms

0.78ms
0.10ms
0.61ms
0.10ms

0.84ms
0.10ms
0.58ms
0.10ms

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Technical Documentation for Customer

Document Identification / Version: V10

3.4.4. MAXIMUM ENERGYZING TIME

3.5. STORAGE SPECIFICATIONS

[-40C, +80C]
6 months

Acceptable storage temperature range

Maximum acceptable storage time

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Document Identification / Version: V10

3.6. CLEANLINESS SPECIFICATIONS

Please refer to chart attached below

Contamination level for fuel rail

Particles specifications
30-60um :
1200 pcs
60-200um : 720 pcs
200-300um : 100 pcs
300-800um : 1 pcs(1 on 5 analyzed part)
>800um : 0 pcs

Fiber specifications
Number of fibers : 25MAX
Shape of fiber (non-metal contamination)
Minimum diameter of fiber : 0.040mm
Maximum size: 1.5mm
The reason why we added MIN diameter is that we don't like the fiber (non-metal contamination) to
get into inside injector and that injector filter can catch the contamination.

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Document Identification / Version: V10

3.7. RELIABILTY
8ppm

0 mileage claim

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Document Identification / Version: V10

4. MOUNTING SPECIFICATIONS
4.1. DETAILED DIMENSIONS OF ENGINE HEAD AND FUEL RAIL

NOTE:
- Recommended axis tolerance of 1.2 has been agreed by RSA for IOD loop.
- Thickness of tolerance ring for Pre-B2/B2 loop sample is thinner by 0.36mm as temporally solution.

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Technical Documentation for Customer

Document Identification / Version: V10

4.2. INJECTOR ASSEMBLY INSTRUCTIONS

Item

Preparation

Installation of
the rail to the
injector

Installation to
the head

Instructions
Confirm that there is no foreign material in the area of injector hole of the engine head,
injector, gas shield part of the injector, O ring, fuel hole of the rail (to secure the gas
shield and fuel shield)
Silicon oil paint on the O ring of the injector
Insert the injector to the rail. Make sure not to incline the injector.
Determine the position for the rotating direction for the nail of the clip to fit the groove of
the rail.
Make a very thin painting of the oil to the engine hole of the head. Too much oil leads
will adhere to the injection portion and create risk for deposit. Thus make sure to avoid
excessive amount of painting.
Insert until the tolerance ring will contact the base surface of the cylinder head.
When inserting the injector to the head, make sure not to damage the front edge of the
part (injection portion).
Make sure to insert straight to the axis line of the injector (no bending stress on the inj.)
If the insertion load is very large, please check the hole diameter, gas shield outer
diameter. Press fitting margin is around 30 to 100m.
Fix the rail to the head with the bolts. When fixing it, make sure that injectors are not
inclined.

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Technical Documentation for Customer

Document Identification / Version: V10

Item

Fuel pressure

Continuously
energize

Other

Attention
Please do not impress fuel pressure more than 30MPa.
If the injector impressed more than 30MPa by mistake, please do not reuse it.
The injector is not designed so that it endures continuously energize. The injector
which continuously energized is necessary to check short-circuit/open-circuit.
Do not use dropped injector
Do not apply excessive axial and radial force and shock to injector.
Do not hit nozzle portion.

4.3. INJECTOR CLIP ASSEMBLY INSTRUCTIONS

700
C lip free length

Spring force[N ]

600

M edian
Low er lim it
U pper lim it

500
400
300
200
100
0
14.5

15.0

15.5

16.0
16.5
Set Length[m m ]

17.0

17.5

18.0

NOTE:
Suitable dimension for Parameters of Spring set force & tolerance of Channel width are necessary to be
defined during development.

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Document Identification / Version: V10

4.4. TEFLON SEAL REPLACEMENT

DENSO recommends to replace Teflon seal every time the injector is removed from the cylinder head.
Tool and procedure to replace Teflon seal are presented below
Procedure to replace Teflon seal:
-

Remove foreign material from 3 tools and injector.

At that time, dont damage 3 tools and injector tip.
Insert the reforming tool in the nozzle.
At that time, dont hit the nozzle tip with the reforming tool.
Install the R side of hole to nozzle tip side.
Insert the metal cap on the injector tip.
At that time, dont hit the nozzle tip with Metal cap.
Insert a Teflon seal from metal cap tip.
At that time, Insert it without a distortion of Teflon seal
Insert the extender on metal cap.
Push Teflon seal by extender and put Teflon seal into the groove on
injector tip.
At that time, Teflon seal is expanded than initial size.
Then remove the extender and the metal cap from the injector tip.
Pull slowly reforming tool and put reforming tool at nozzle groove and
Teflon seal.
Maintain it more than 30 seconds.
Then the Teflon seal is reformed to the suitable outer diameter.

NOTE:
- Do not use the injector without reforming the Teflon seal after
replacing the Teflon seal.
- Use a soft brush when cleaning up the inside of reformatory tool to
avoid the damage of the surface.

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