Technical and repair information surrounding Denso Common Rail injectors outside of the Denso network is limited and scarce, yet their use and presence within the Australasian diesel market is widespread.
The following document aims to provide a guide to using the tooling and shim kits together with genuine and non‐genuine parts, to strip, rebuild and test Denso ‘G2’ type common rail injectors. The information herein has been gained from the dismantling, rebuild and consequent flow and response testing of new Denso CR injectors using the Hartridge Cri‐PC and IFT‐70 all‐makes programme. Alterations to the shim adjustment of individual injectors were made and the results recorded. These results have been used to determine what effects any changes to the shim adjustment have on the overall performance of the injector.
Correction codes (QR codes) cannot be written and produced for any Denso injector using this information. The production and creation of QR codes requires complex software and intricate flow testing using genuine Denso/Hartridge authorised equipment. Denso CR injector repair involves stringent clean room practices and very tight quality control on build tolerances. Please take this into consideration when attempting any dismantling of Denso CR injectors.
Hopefully this guide will provide an insight into what can be achieved with tooling available outside of the Denso official repair programme. Consideration should be given to the importance of correction codes when undertaking any adjustment or unofficial repair of ANY common rail injector that uses a correction code.
