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CRM-100
Common Rail Injector Repair Tool Sets
Instruction Manual

DENSO G2 Injectors

INJECTRONI CO., LTD.

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1. Injector body
2. Valve plunger
3. Dowel
4. Calibration shim, B23, ID3.15mm, OD
5.75mm, thickness 1.0-2.5mm
5. Spring
6. spacer
7. Nozzle
8. Nozzle nut
9. O-ring
10. Copper washer
11. Plastic cap
12. Solenoid
13. Calibration shim, B24, ID 1.7mm, OD
3.95mm, thickness 1.0-1.5mm
14. Spring
15. Armature
16. Ball
17. Nut
18. Valve spacer
19. Dowel
20. O-ring
21. Calibration shim, B27, ID 21.5mm,
OD 24.3mm, thickness 1.5-1.72mm

To measure total 3 calibration shims

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Working Procedure – on Nozzle Side

Task 1 – Adjust Needle Opening Pressure (1)

1. Clamp injector on a vise with injector clamping tool.

Loose nozzle nut (8)

2. Remove calibration shim B23 (4)

3. Install micrometer with extension rode 511012 on

frame 970100. Place platform 511020 on frame 970100.

Adjusting micrometer height by the hand wheel, then
lock the moving beam by the handles. Zero
micrometer on platform 511020.

Caution: Pay close attention when adjusting micrometer

mounting arm downward, to prevent micrometer damage.

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Working Procedure – on Nozzle Side

Task 1 – Adjust Needle Opening Pressure (2)

4. Measure the thickness of shim B23

5. Fasten injector by using the matching holder on

frame 970100.

6. Place shim B23 (4) and spring (5) in injector cavity.

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Working Procedure – on Nozzle Side

Task 1 – Adjust Needle Opening Pressure (3)

7. Place 1mm thickness gauge on the injector.

Adjusting the position of micrometer. Zero

micrometer on the thickness gauge.

8. Remove the thickness gauge. Place spacer (6) in

injector

9. Place 1mm thickness gauge on it. Measure the top

of thickness gauge.

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Working Procedure – on Nozzle Side

Task 1 – Adjust Needle Opening Pressure (4)

10. If the measured value does not meet requirement,

replace calibration shim B23 with thickness indicated

on PC screen

11. Fasten nozzle nut with torque 90Nm

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Working Procedure – Solenoid Side

Task 2 – Inspect Weariness of Valve Spacer (1)

1. Loose solenoid (12) from injector.

2. Remove calibration shim B27 (21), calibration shim

B24 (13), spring (14), armature (15), and ball(16)

3. Loose nut (17) by using special tool.

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Working Procedure – Solenoid Side

Task 2 – Inspect Weariness of Valve Spacer (2)

4. Remove valve spacer (18). Check the sealing

surface by using the microscope

5. The spacer with light weariness is still usable.

Replace the severe worn one with new part.

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Working Procedure – Solenoid Side

Task 2 – Inspect Weariness of Valve Spacer (3)

6. Place The ball (16), with flat surface up, on the

cavity at the end cavity of armature (15 ).

7. It is wrong to place the ball with spherical

surface up.

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Working Procedure – Solenoid Side

Task 3 – Adjust Armature Lift (1)

1. Zero micrometer on platform 511020

2. Measure the thickness of shim B27

3. Fasten sleeve 970539 and extension probe 511011

on micrometer

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Working Procedure – Solenoid Side

Task 3 – Adjust Armature Lift (2)

4. Zero micrometer on platform 511020

5. Measure solenoid.

Note: DO NOT place shim B27 in the cavity of solenoid

6. Zero micrometer on platform 511020

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Working Procedure – Solenoid Side

Task 3 – Adjust Armature Lift (3)

7. Place shim B27 in the cavity of injector. Measure

injector

8. If the measured value does not meet requirement,

replace calibration shim B27 with thickness

indicated on PC screen. Tighten solenoid with torque
12-15Nm.

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Working Procedure – Solenoid Side

Task 4 – Adjust Solenoid Spring Compression (1)

1. Fasten micrometer and platform 511020 on frame

970100. Zero micrometer on platform

2. Measure thickness of shim B24 (13)

3. Fasten sleeve 970539 and extension rod 511011 on

micrometer.

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Working Procedure – Solenoid Side

Task 4 – Adjust solenoid spring Compression (2)

4. Place shim B27 in to cavity of solenoid.

5. Hold micrometer with sleeve 970539 firmly against

solenoid. Zero micrometer.

6. Place spring (14) and shim B27(13) in solenoid

cavity.

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Working Procedure – Solenoid Side

Task 4 – Adjust solenoid spring Compression (2)

7. Measure solenoid. If the measured value does not

meet requirement, replace calibration shim B24 with
thickness indicated on PC screen

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Working Procedure – Solenoid Side

Task 5 – Adjust Armature Lift by Electronic Driving Signal (1)

1. Loose the screw on the top center of solenoid.

2. Fasten injector by a matching holder on frame

970100. Connect injector terminal and C-Box with

cable.

3. Click the button on PC screen to trig electronic

driving signal. The measurement of armature lift will

be done automatically by the system.

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Working Procedure – Solenoid Side

Task 5 – Adjust Armature Lift by Electronic Driving Signal (2)

4. If measured value does not meet required armature

lift, loose solenoid from injector body. Replace shim

B27 by system recommendation.

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CRM-100 Common Rail Injector Measurement System