THZ98-02 SERVICE BULLETIN FUEL INJECTION PUMP TECHNICAL HINT DENSO AUTHORIZED SERVICE DEALER ONLY SUBJECT: Procedure for Servicing 2-spring Nozzles and Nozzle Holders 1. Outline This manual describes the 2-spring nozzles and nozzle holders and explains their repair and adjustment methods by citing their representative models as examples. While the nozzles that are currently used can be broadly divided into two types, there are four types of adjustment methods. Thus, for an effective operation, refer to this manual before performing a repair. 2. Models and Types of 2-spring Nozzles and Nozzle Holders Nozzle holder model Nozzle model Construction Type Capsule type (conventional type) I DLL-P* Shim adjustment (reinforced type) II Shim adjustment (conventional type) III KBL, KBAL DLL-S* Shim adjustment (reinforced type) IV * Differences in nozzle models Sizes: Nozzles come in size P, R, S, T, U, V, or W, which designates the outer diameter dimension of the collar portion of the nozzle body. For most automotive applications, nozzles sized P or S are used. Size symbol ød (mm) P 14.3 R 16 S 17 T 22 U 30 V W 42 50 Advice: To adjust the pre-lift, the conventional type uses a pre-lift adjustment shim and the reinforced type uses a pre-lift adjustment spring seat. TW 98-06 December,1999
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THZ98-02
SERVICE BULLETINFUEL INJECTION PUMP
TECHNICAL HINT
DENSO AUTHORIZED SERVICE DEALER ONLY
SUBJECT: Procedure for Servicing 2-spring Nozzles and Nozzle Holders
1. OutlineThis manual describes the 2-spring nozzles and nozzle holders and explains their repair andadjustment methods by citing their representative models as examples.While the nozzles that are currently used can be broadly divided into two types, there are fourtypes of adjustment methods. Thus, for an effective operation, refer to this manual beforeperforming a repair.
2. Models and Types of 2-spring Nozzles and Nozzle Holders
Nozzle holder model Nozzle model Construction Type
Capsule type (conventional type) IDLL-P*
Shim adjustment (reinforced type) IIShim adjustment (conventional type) III
KBL, KBALDLL-S*
Shim adjustment (reinforced type) IV
* Differences in nozzle models
Sizes:Nozzles come in size P, R, S, T, U, V, or W, whichdesignates the outer diameter dimension of the collarportion of the nozzle body. For most automotiveapplications, nozzles sized P or S are used.
Size symbol ød (mm)P 14.3R 16S 17T 22U 30VW
4250
Advice:To adjust the pre-lift, the conventional type uses a pre-lift adjustment shim and the reinforcedtype uses a pre-lift adjustment spring seat.
TW 98-06December,1999
3. Adjustment Method and Applicable Engine Model by Construction Type
Type Construction Representative engine model Manufacturer1Z, 1HD-T TOYOTA
I Capsule type (con-ventional type) 4D32, 4D33, 4D33-2, 4D35 MITSUBISHI
1HD-FT, 15B-F, 15B-FT TOYOTAII
Shim adjustment(reinforced type) 4D33-4, 4D34T4, 4D35, 4M5# series MITSUBISHI
IV Shim adjustment(reinforced type) 6D16T6 MITSUBISHI
4. STT Application
No. Part Name DENSO P/N Type I Type II Type III Type IV1 2-spring nozzle adjustment tool 95091-107702 2-spring tool set* 95093-00040
2-1 2-spring base 95093-102302-2 2-spring box 95093-102502-3 Measure attachment 95093-103002-4 Straight pin 95094-100702-5 Dial gauge 95800-100503 Master spring seat 95093-103304 Base 95093-201805 Dial gauge holder unit 95800-200106 Probe joint 95800-200207 Probe 95800-200308 Socket wrench 95991-10150
*2-spring tool set is composed of 2-1, 2-2, 2-3, 2-4 and 2-5 .
5. ConstructionA 2-spring nozzle holder contains two springs to enable the nozzle needle to be lifted in twostages in accordance with the pressure in the injection pipe.To show its construction, an example of a nozzle and nozzle holder (type II, reinforced) used onthe 1HD-FT engine is given below. Although there are some differences in construction and op-eration by type, they are all identical in principle.
6. OperationThe sequence of operations from the time the fuel is pumped until the injection is completed isindicated below:(1) The high-pressure fuel that has been pumped by the injection pump travels via the injection
pipe and enters the nozzle body.(2) The injection pipe pressure rises, becomes greater than the first valve opening pressure (the
force of the first spring), and lifts the nozzle needle.(3) Pushed by the nozzle needle, the maximum lift adjustment washer rises only for the
amount of "pre-lift: a", and upon coming in contact with the pre-lift adjustment springseat, the nozzle needle stops momentarily.
(4) The injection pipe pressure rises further, becomes greater than the second valve openingpressure (the resultant force of the first and second springs), and lifts the nozzle needlefurther.
(5) Pushed by the nozzle needle, the maximum lift adjustment washer and the pressure pinascend only for the amount of "maximum lift: L", and the nozzle needle comes to a stop.
(6) The pumping of fuel ends and the injection pipe pressure becomes lower than the secondopening valve pressure (the resultant force of the first and second springs).
(7) Pushed by the second spring, the pre-lift adjustment spring seat, the maximum liftadjustment washer, and the nozzle needle are pushed further by the first spring. As aresult, the pressure pin and the nozzle needle descend, thus completing the injection.
The sequence of operations described above can beexplained more simply as follows:
•It is the resultant force of the first and secondsprings that determines the second valve openingpressure. To adjust this pressure, the second valveopening pressure adjustment shim is used tochange the set load of the second spring
•To adjust the amount of pre-lift, the pre-lift adjust-ment spring seat is used.
•It is the resultant force of the first and secondsprings that determines the second valve openingpressure. To adjust this pressure, the second valveopening pressure adjustment shim is used tochange the set load of the second spring
•The amount of maximum lift is adjusted by using themaximum lift adjustment washer.
7. Adjustment Procedure by Type7-1. Type I (Capsule Type)Construction Diagram
Pull out the first pressurespring and the first valveopening pressureadjustment shim, loosen theplug screw one to two turns,and measure the valveopening pressure
Assemble parts other than thehollow screw and measure thevalve opening pressure.
AdjustmentMethod
Select a pre-liftadjustment shim (thethicker the shim, thesmaller the pre-lift will be).
Select a second valveopening pressureadjustment shim (the thickerthe shim, the higher thevalve opening pressure willbe).
Select a first valve openingpressure adjustment shim (thethicker the shim, the higher thevalve opening pressure will be).
*2-spring tool set is composed of No. 1, 2, 3, 4 and 5.
Detailed Adjustment Procedure(For 093500-4491 as an example)
(1) Pre-lift adjustment1) Assemble the STT on the dial gauge so that
the distance between the probe and the end ofthe STT is 2mm or less.
2) On a base plate or STT, set the dial gaugegraduation to zero.
3) Assemble the nozzle, tip packing, and straightpin on the STT, and install the first pressure pin
4) Align the hole of the STT with the straight pinand measure the dimension L2.
5) Assemble the STT on the dial gauge so that thedistance between the probe and the end of the
STT is 7mm or more.
6) On a base plate or STT, set the dial gaugegraduation to zero.
7) Assemble the capsule sub-assembly.Assemble the second pressure pin, the secondpressure spring, and the second valve openingpressure adjustment shim on the capsulescrew, and use the STT to tighten the plugscrew.
• Tightening torque: 0.2 – 0.3kgf•m
Advice:If the thickness of the second valve openingpressure adjustment shim is unknown, use1.5mm as a nominal value.
8) Assemble the pre-lift adjustment shim, thecapsule sub-assembly, and the straight pin inthe nozzle holder body
9) Alight the straight pin with the hole of the STTand measure the dimension L1.
10) Using dimensions L1 and L2 obtained in steps"4)" and "9)", calculate the amount of pre-lift a.•Pre-lift a = L1 – L2•Pre-lift a (specified value) = 0.08 ± 0.02mm
11) If the amount of pre-lift deviates from thespecified value, adjust it by changing thepre-lift adjustment shim to one with a differentthickness.
Advice:The thicker the pre-lift adjustment shim, thesmaller the pre-lift will be.
Caution:Because adjusting the pre-lift requires highprecision, thoroughly clean the parts andmake sure that they are free of foreignobjects before performing the operation.
2) Second valve opening pressure adjustment1) Loosen the plug screw of the capsule sub-
assembly one to two turns.
Advice:After the plug screw has been loosened one totwo turns, the amount of pre-lift will be 0mmwhen it is installed in the nozzle holder.
2) In the nozzle holder body, install the pre-liftadjustment shim that was selected in section"(1)", the capsule sub-assembly in the statedescribed in "1)", the first pressure pin, tippacking, straight pin, and the nozzle. Then,tighten the retaining nut
Advice:At this time, do not install the first pressurespring and the first valve opening pressureadjustment shim.
• Tightening torque: 2.5 – 3.5kgf•m
3) On the nozzle hand tester, install the nozzleand the nozzle holder that were installed in "2)",and measure the valve opening pressure.
• Second valve opening pressure(specified value): 138 – 148kgf/cm2
4) If the pressure deviates from the specifiedvalue, adjust it by changing the second valveopening pressure adjustment shim to one witha different thickness.
Caution:Make sure to loosen the plug screw one totwo turns before assembling the capsulesub-assembly by changing the second valveopening pressure adjustment shim.
5) After completing the second valve openingpressure adjustment, remove the capsulesubassembly from the nozzle and nozzleholder. Then, use the STT to tighten the plugscrew
• Tightening torque: 0.2 – 0.3kgf•m
(3) First valve opening pressure adjustment1) In the nozzle holder body, install the pre-lift
adjustment shim that was selected in section"(1)", the capsule sub-assembly that wasadjusted in section "(2)", the first valve openingpressure adjustment shim, the first pressurespring, the first pressure pin, the tip packing,the straight pin, and the nozzle. Then, tightenthe retaining nut.
•Tightening torque: 2.5 – 3.5kgf•m Advice:If the thickness of the first valve openingpressure adjustment shim is unknown, use1.5mm as a nominal value.
2) On the nozzle hand tester, attach the nozzleand the nozzle holder that were installed in"1)", and adjust the valve opening pressure.
•First valve opening pressure: 165 –175kgf/cm2
3) If the pressure deviates from the specifiedvalue, adjust it by changing the first valveopening pressure adjustment shim to one witha different thickness.
7-2. Type II (Reinforced Type)Construction Diagram
Constituent Parts and Names
No. Name1 Hollow screw2 Washer3 Nozzle holder body
4 First valve opening pressureadjustment shim
5 First spring6 Pressure pin7 Spring seat
8 Second valve openingpressure adjustment shim
9 Second spring
10 Pre-lift adjustment springseat
11 Tip packing
12 Maximum lift adjustmentwasher
13 Straight pin14 Nozzle
15 Retaining nut
Adjustment Procedure (Summary)
AdjustmentSequence 1. Maximum Lift 2. Pre-lift 3. Second Valve
Opening Pressure
4. First ValveOpeningPressure
MeasurementMethod
Measure the needlerecession dimensionL1, the tip packinggroove depth L2, andthe maximum liftadjustment washerthickness L3, in orderto calculate themaximum lift (L1 + L2)- L3.
Measure the tippacking thicknessL4 and the springseat leg length L5in order tocalculate the pre-lift: L4 - L5 - (L3-L1)
Pull out the first valveopening pressure adjust-ment shim, the first spring,and the pressure pin.Replace the pre-liftadjustment spring seat withthe master spring seat(STT) and measure thevalve opening pressure.
Assemble all parts andmeasure the valveopening pressure
AdjustmentMethod
Select a maximum liftadjustment washer.
Select a pre-liftadjustment springseat.
Select a second valveopening pressure adjust-ment shim
Select a first valveopening pressure ad-justment shim.
Micrometer Master spring seat(STT: 95093-10330)Nozzle hand tester
Nozzle hand tester
STTNo. Part Name DENSO P/N
1 Master spring seat 95093-103302 2-spring base 95093-102303 Measure attachment 95093-103004 Dial gauge 95800-10050
Detailed Adjustment Procedure(For 093500-6010 as an example)
(1) Maximum lift adjustment1) Attach the measure attachment (STT) to the
dial gauge.
2) Place the nozzle on the 2-spring base (STT),and place the pre-lift adjustment spring seat asindicated by "A" in the diagram on the right.
3) Align the hole of the measure attachment (STT)with the pre-lift adjustment spring seat and setthe graduation on the dial gauge to zero.
4) Place the pre-lift adjustment spring seat byfacing it in the opposite direction ("B" in thediagram on the right). Align the hole of themeasure attachment (STT) with the pre-liftadjustment spring seat and measure L1.
5) Place the nozzle body (nozzle needle removed)on the 2-spring base (STT) and place the tippacking (groove facing up) as shown in thediagram on the right.
6) On the 2-spring base (STT), set the graduationof the dial gauge to zero.
7) Place the needle of the dial gauge so that itcomes in contact with the groove of the tippacking and measure L2
8) Using a micrometer, measure the thickness L3of the maximum lift adjustment washer.
9) Calculate the maximum lift according to themeasured L1, L2, and L3.
• Specified value: (L1 + L2) – L3 = 0.23 – 0.28mm
10) If the amount of maximum lift deviates fromthe specified value, adjust it by changing themaximum lift adjustment washer to one with adifferent thickness.
Caution:Make sure to install the maximum lift adjust-ment washer correctly (chamfer facing thenozzle), as it could lead to damage or otherproblems if it is installed upside down.
2) Pre-lift adjustment1) Using a micrometer, measure the thickness L4
of the tip packing.2) Using a micrometer, measure the length L5 of
the leg of the pre-lift adjustment spring seat.3) Calculate the amount of pre-lift according to
the measured L1, L3, L4, and L5.•Specified value:
L4 – L5 – (L3 – L1) = 0.085 – 0.105mm
4) If the amount of pre-lift deviates from the specified value, adjust it by changing the pre-liftadjustment spring seat to one with a different thickness
(3) Second valve opening pressure adjustment1) In the nozzle holder body, install the spring seat, the second valve opening pressure
adjustment shim, the second spring, master spring seat (STT), the straight pin, the tippacking, the maximum lift adjustment washer, and the nozzle. Then, tighten the retainingnut.•Tightening torque: 2.5 – 3.5kgf•m
2) On the nozzle hand tester, install the nozzle and nozzle holder that were assembled instep "1)", and measure the second valve opening pressure.
•Second valve opening pressure: 235 – 245kgf/cm2
Caution:For production number ’97/9 and thereafter, the second valve opening pressure hasbeen changed in accordance with the change in the shape of the part. Therefore,refer to "8. Reference Material" at the end of the manual for the specified value.
3) If the pressure deviates from the specified value, adjust it by changing the second valveopening pressure adjustment shim to one with a different thickness.
Advice:Using a shim that is thicker by 0.05mm increases the valve opening pressure byapproximately 7.6kgf/cm2.
(4) First valve opening pressure adjustment1) In the nozzle holder body, install the first valve opening pressure adjustment shim, first
spring, pressure pin, spring seat, second valve opening pressure adjustment shim,second spring, pre-lift adjustment spring seat, straight pin, tip packing, nozzle maximumlift adjustment washer, and the nozzle. Then, tighten the retaining nut.•Tightening torque: 2.5 – 3.5kgf•m
2) Attach onto the nozzle hand tester the nozzle and the nozzle holder that were installed instep "1)", and measure the first valve opening pressure.•First valve opening pressure: 180 – 190kgf/cm2
3) If the pressure deviates from the specified value, adjust it by changing the first valveopening pressure adjustment shim to one with a different thickness.
Advice:Using a shim that is thicker by 0.05mm increases the valve opening pressure byapproximately 7.6kgf/cm
7-3. Type III (Conventional Type)Construction Diagram
Constituent Parts and Names
No. Name1 Hollow screw2 Washer3 Cap nut4 Washer5 Locknut6 Plug screw7 Spring seat
8 Second valve opening pressureadjustment shim
9 Second pressure spring10 Second pressure pin11 Pre-lift adjustment shim12 Capsule screw13 First pressure spring14 First pressure pin15 Inlet connector16 Washer17 Nozzle holder body18 Nozzle assembly19 Retaining nut
Adjustment Procedure (Summary)
AdjustmentSequence 1. Maximum Lift
2. Second Valve Openin5gPressure
3. Pre-lift4. First Valve
OpeningPressure
MeasurementMethod
Pull out the plugscrew, the secondvalve openingpressure adjustmentshim, the secondpressure spring, thesecond pressure pin,and the pre-liftadjustment shim; then,measure the valveopening pressure
Set the pre-lift to zero bypulling out the pre-lift ad-justment shim; then,measure the valve open-ing pressure.
Measure theamount ofdeflection of thedial gauge with thepre-lift adjustmentshim removed andinstalled.
Assemble all parts andmeasure (verify) thevalve opening pressure.
AdjustmentMethod
Adjust with thecapsule screw(tightening the screwincreases the valveopening pressure)
Select a second valveopening pressure adjust-ment shim (the thickerthe shim the higher thevalve opening pressurewill be)
Select a pre-lift ad-justment shim (thethicker the shimthe greater thepre-lift will be).
_
Tools
Nozzle hand tester Nozzle hand tester 2-spring nozzleadjustment tool(STT: 95091-10770)Dial gauge
Nozzle hand tester
STT
No. Part Name DENSO P/N
1 2-spring nozzleadjustment too 95091-10770
2 Dial gauge 95800-10050
Detailed Adjustment Procedure(For 093500-3090 as an example)
(1) First valve opening pressure adjustment1) Assemble the nozzle and the first pressure pin
on the nozzle holder and tighten them with theretaining nut.
•Tightening torque: 6.0 – 8.0kgf•m2) Insert the first pressure spring and install the
capsule screw.
3) Place it on the nozzle hand tester, and regulatethe amount in which to screw in the capsulescrew in order to adjust the first valve openingpressure.
Advice:Screwing in the capsule screw increases thefirst valve opening pressure.
•First valve opening pressure: 180 –188kgf/cm2
4) Tighten the locknut to secure the capsule screwin place.
• Tightening torque: 6.0 – 7.0kgf•m
(2) Second valve opening pressure adjustment1) Assemble the second pressure pin, second
pressure spring, and the second valve openingpressure adjustment shim. Then, tighten theplug screw until it comes in contact with thecapsule screw
Caution:At this time, do not install the pre-lift adjust-ment shim.
Advice:If the thickness of the second valve openingpressure adjustment shim that was installed isunknown, use 1.9mm as a nominal value.
2) Place it on the nozzle hand tester andmeasure the second valve opening pressure.
•Second valve opening pressure:254 – 262kgf/cm2
3) If the pressure deviates from the specifiedvalue, adjust it by changing the second valveopening pressure adjustment shim to one witha different thickness.
Advice:Although the relationship between shimthickness and valve opening pressure differsfrom product to product, the pressure changesapproximately 1.1 kgf/cm2 for every 0.01mm ofshim thickness.
(3) Pre-lift adjustment1) Remove the plug screw, second valve opening
pressure adjustment shim, and the secondpressure spring.
2) Place the dial gauge, probe, and the gaugeholder on the nozzle holder.
3) Set the dial gauge graduation to zero (repeatthis process two or three times).
4) Remove the second pressure pin and installthe pre-lift adjustment shim.
5) Similar to step "3)", place the dial gauge andmeasure the amount of pre-lift.
•Pre-lift: 0.08 – 0.12mm
Advice:If the thickness of the pre-lift adjustment shimthat was installed is unknown, use 1.1mm as anominal value.
6) If the amount of pre-lift deviates from thespecified value, adjust it by changing the pre-lift adjustment shim to one with a differentthickness.
Advice:If the amount of pre-lift is greater than thespecified value, use a thinner shim. If it issmaller than the specified value, use a thickershim.
(4) First valve opening pressure verification1) Install the pre-lift adjustment shim, the second
pressure pin, the second pressure spring, andthe second valve opening pressure adjustmentshim; then, tighten the plug screw.
• Tightening torque: 3.0 – 4.0kgf•m2) Using a washer in between, install the cap nut. • Tightening torque: 4.0 – 5.0 kgf•m
Caution:1. Make sure to use a pre-lift adjustment
shim and a second valve openingpressure adjustment shim as determinedin the previously mentioned adjustmentprocess.
2. Be careful in distinguishing a pre-liftadjustment shim and a second valveopening pressure adjustment shim, asboth have the same size and shape
3) Place the nozzle on the nozzle hand tester andverify that the first valve opening pressure hasthe following value:
•First valve opening pressure: 180 – 188kgf/cm2
Caution:If the pressure deviates from the specifiedvalue, repeat the adjustment process fromthe beginning.
7-4. Type IV (Reinforced Type)Construction Diagram
Constituent Parts and Names
No. Name1 Nozzle holder body2 Pressure pin3 Spring seat4 First pressure spring5 Second pressure spring
Measure the amountof deflection of the dialgauge with the pre-liftadjustment shimremoved and installed.
Pull out the pre-liftadjustment shim, thesecond valve openingpressure adjustmentshim, the spring seat,and the second pressurespring; then, measurethe valve openingpressure.
Pull out the pre-liftadjustment shim andmeasure the valveopening pressure.
Install all parts andmeasure (verify) thevalve openingpressure.
AdjustmentMethod
Select a pre-liftadjustment shim.
Adjust with the first valveopening pressure adjust-ment screw.
Select a second valveopening pressureadjustment shim. _
Nozzle hand tester Nozzle hand tester Nozzle hand tester
STT
No. Part Name DENSO P/N
1 2-spring base 95093-10230
2 Base 95093-201803 Dial gauge holder unit 95800-200104 Probe joint 95800-200205 Probe 95800-200306 Socket wrench 95991-10150
Detailed Adjustment Procedure(For 093500-4880 as an example)
(1) Pre-lift adjustment1) Render the distance between the probe and
the end of the STT to be approximately 0mm;then install the STT on the dial gauge.
2) Install the nozzle assembly, the tip packing,and the spring seat on the STT
3) Align the hole of the STT with the pin of the tippacking and set the dial gauge graduation tozero.
4) Select a pre-lift adjustment shim that is thickerthan the clearance between the tip packingand the spring seat. Then install the shimbetween the tip packing and the spring seat.
Advice:Select and install a pre-lift adjustment shim witha nominal value of 1.5mm.
5) Using a dial gauge, measure the amount ofpre-lift. Then, replace the pre-lift adjustmentshim with one of a different thickness in order toattain the specified value indicated below.• Specified value: 0.095 ± 0.015mm
Advice:Using a thicker pre-lift adjustment shimincreases the amount of pre-lift.
Caution:Because adjusting the pre-lift requires highprecision, thoroughly clean the parts andmake sure that they are free of foreignobjects before performing the operation.
(2) First valve opening pressure adjustment1) Install the nozzle assembly and the tip packing
in the nozzle holder body. Using the STT,tighten the retaining nut.
• Tightening torque: 6.0 – 8.0kgf•m
2) Insert the pressure pin into the nozzle holderbody. Then, insert the first pressure spring,install the first valve opening pressureadjustment screw, and tighten it until it comesin contact with the first pressure spring.
3) Place it on the nozzle hand tester, and regulatethe amount in which to screw in the first valveopening pressure adjustment screw in order toadjust the first valve opening pressure.• First valve opening pressure: 150 – 158kgf/cm2
4) Using the copper plate washer and the cap nut,secure the first valve opening pressureadjustment screw in place.
• Tightening torque: 4.0 – 5.0kgf•m
(3) Second valve opening pressure adjustment1) In the nozzle holder body, install the second
valve opening pressure adjustment shim, thesecond pressure spring, the spring seat, thetip packing, and the nozzle assembly. Then,use the STT to tighten the retaining nut.
• Tightening torque: 6.0 – 8.0kgf•m
Caution:Do not install the pre-lift adjustment shim.
Advice:If the thickness of the second valve openingpressure adjustment shim that was installed isunknown, use 1.4mm as a nominal value.
2) Place it on the nozzle hand tester and measurethe second valve opening pressure.• Second valve opening pressure:
281 – 289kgf/cm2
3) If the pressure deviates from the specifiedvalue, adjust it by changing the second valveopening pressure adjustment shim to one witha different thickness.
Advice:Although the relationship between shimthickness and valve opening pressure differsfrom product to product, the pressure changesapproximately 0.9 kgf/cm2 for every 0.01mm ofshim thickness.
4) First valve opening pressure verification1) Install the pre-lift adjustment shim that was
used in the adjustment in section (1).
2) Place it on the nozzle hand tester and verifythat the first valve opening pressure has thevalue indicated below.
• First valve opening pressure: 150 – 158kgf/cm2
8. Reference Material8-1. List of Adjustment Values