{"id":2923,"date":"2023-11-17T23:50:56","date_gmt":"2023-11-17T22:50:56","guid":{"rendered":"https:\/\/mbci.mackuz.ovh\/?p=2923"},"modified":"2023-11-17T23:50:56","modified_gmt":"2023-11-17T22:50:56","slug":"disassembly-cleaning-assembly-and-adjustment-of-injection-nozzles","status":"publish","type":"post","link":"https:\/\/mbci.mackuz.ovh\/index.php\/2023\/11\/17\/disassembly-cleaning-assembly-and-adjustment-of-injection-nozzles\/","title":{"rendered":"Disassembly, cleaning, assembly and adjustment of injection nozzles"},"content":{"rendered":"

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07.1\u2014137 Disassembly, cleaning, assembly and adjustment of injection nozzles<\/strong><\/div>\n
Job no. of flat rates or standard texts and flat rates data 07-6750 or 6752.<\/div>\n<\/div>\n<\/td>\n
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Testing data, injection<\/strong><\/div>\n<\/div>\n<\/td>\n
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nozzles<\/strong><\/div>\n<\/div>\n<\/td>\n
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Bosch designation<\/div>\n<\/div>\n<\/td>\n
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Injection pressure in bar positive * for new injection nozzles<\/div>\n<\/div>\n<\/td>\n
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for old injection nozzles, min.<\/div>\n<\/div>\n<\/td>\n
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DNOSD2402<\/sup>) DNO SD 2400<\/div>\n<\/div>\n<\/td>\n
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135-143<\/div>\n<\/div>\n<\/td>\n
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DNOSD 240\/3<\/sup>)<\/div>\n<\/div>\n<\/td>\n
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2<\/sub>> The difference between any two injection nozzles within one engine must not exceed 5 bar positive. ) Starting production code no. 928 or 041.. ) Starting November 1981 with center hole 0.20 mm dia. (formerly 0.15 mm dia.)<\/div>\n<\/div>\n<\/td>\n
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Tightening torques<\/strong><\/div>\n<\/div>\n<\/td>\n
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Nm<\/strong><\/div>\n<\/div>\n<\/td>\n
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Injection nozzles, upper and lower parts<\/div>\n<\/div>\n<\/td>\n
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70-80<\/strong><\/div>\n<\/div>\n<\/td>\n
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Special tools<\/strong><\/div>\n<\/div>\n<\/td>\n
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Socket 27 <\/strong>mm, 1\/2″ drive<\/div>\n<\/div>\n<\/td>\n
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11004-6193<\/div>\n<\/div>\n<\/td>\n
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001 589 65 09 00<\/strong><\/div>\n<\/div>\n<\/td>\n
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Cleaner<\/div>\n<\/div>\n<\/td>\n
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000 589 00 68 00<\/div>\n<\/div>\n<\/td>\n
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Conventional tools<\/strong><\/div>\n<\/div>\n<\/td>\n
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Torque wrench 1\/2″ drive, 40-130 Nm<\/div>\n<\/div>\n<\/td>\n
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Tester EFEP 60 H<\/strong><\/div>\n<\/div>\n<\/td>\n
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e.g. Bosch, D-7000 <\/strong>Stuttgart, Order No. \"\"<\/span>\"\"\"\"\"\"\"\"\"\"\"\"<\/span><\/span>\"\"\"\"\"\"\"\"\"\"0 681 200 502<\/span>\"\"<\/span><\/span><\/span><\/div>\n<\/div>\n<\/td>\n
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Cleaning needles 0.13 <\/strong>mm dia.<\/div>\n<\/div>\n<\/td>\n
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e.g. Bosch, D-7000 <\/strong>Stuttgart, Order No. KDEP 2900\/3<\/strong><\/div>\n<\/div>\n<\/td>\n
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Cleaning needles 0.18 mm dia.<\/div>\n<\/div>\n<\/td>\n
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e.g. Bosch, D-7000 Stuttgart Order No. KDEP 2900\/5<\/div>\n<\/div>\n<\/td>\n
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07.1.8-137\/1 F3<\/div>\n<\/div>\n<\/td>\n
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Note<\/strong><\/div>\n
The engine is equipped with a center hole pintle nozzle which is distinguished from the standard pintle by a cross hole and a center hole (14 and 15) in the thrust pin. Moreover, a maintenance-free edge filter (13) is pressed into upper part (7) of the in\u00adjection nozzle holder.<\/div>\n<\/div>\n<\/td>\n
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1\u00a0 \u00a0 Needle valve<\/div>\n
2\u00a0 \u00a0 Nozzle body<\/div>\n
3\u00a0 \u00a0 Nozzle holder insert<\/div>\n
4\u00a0 \u00a0 Thrust pin<\/div>\n
5\u00a0 \u00a0 Injection nozzle holder, lower part<\/div>\n
6\u00a0 \u00a0 Compression spring<\/div>\n
7\u00a0 \u00a0 Injection nozzle holder, upper part<\/div>\n
8\u00a0 \u00a0 Leak-off connection<\/div>\n
9\u00a0 \u00a0 Fuel inlet<\/div>\n
10\u00a0 \u00a0Steel shim<\/div>\n
11\u00a0 \u00a0 Annular groove and inlet ports<\/div>\n
12\u00a0 \u00a0 Pressure chamber in nozzle body<\/div>\n
13\u00a0 \u00a0 Edge filter<\/div>\n
14\u00a0 \u00a0 Cross hole<\/div>\n
1 5\u00a0 \u00a0Center hole<\/div>\n<\/div>\n<\/td>\n
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Disassembly<\/strong><\/div>\n<\/div>\n<\/td>\n
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1<\/strong>\u00a0 \u00a0 \u00a0 \u00a0 Clamp upper part (7) of injection holder in vise so that leak-off connections cannot be damaged.<\/div>\n
2\u00a0 \u00a0 \u00a0 \u00a0 Using socket, release and unscrew lower part (5) of injection nozzle holder.<\/div>\n<\/div>\n<\/td>\n
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5 Injection nozzle holder, lower part 7 Injection nozzle holder, upper part<\/div>\n<\/div>\n<\/td>\n
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3 Remove steel shim (10), compression spring (6), thrust pin (4), nozzle holder insert (3) and nozzle body (2) together with needle valve (1).<\/strong><\/div>\n
Attention:<\/strong><\/div>\n
When disassembling nozzle, be sure to keep nozzle body, needle valve and all other parts in correct order.<\/div>\n<\/div>\n<\/td>\n
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07.1.8-137\/2 F3<\/div>\n<\/div>\n<\/td>\n
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Cleaning<\/strong><\/div>\n<\/div>\n<\/td>\n
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4 <\/strong>Using brass brush, remove carbon deposits from end face of nozzle body (2), chiefly around nozzle orifice.<\/div>\n
Using surface plate, check nozzle holder insert (3) and nozzle body (2) for truth at both ends.<\/div>\n<\/div>\n<\/td>\n
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1<\/div>\n<\/div>\n<\/td>\n
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Needle valve<\/div>\n<\/div>\n<\/td>\n
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Fuel inlet<\/div>\n<\/div>\n<\/td>\n
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2<\/div>\n<\/div>\n<\/td>\n
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Nozzle body<\/div>\n<\/div>\n<\/td>\n
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Steel shim<\/div>\n<\/div>\n<\/td>\n
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Nozzle holder insert<\/div>\n<\/div>\n<\/td>\n
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Annular groove and<\/div>\n<\/div>\n<\/td>\n
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Thrust pin<\/div>\n<\/div>\n<\/td>\n
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inlet ports<\/div>\n<\/div>\n<\/td>\n
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5<\/div>\n<\/div>\n<\/td>\n
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Injection nozzle holder,<\/div>\n<\/div>\n<\/td>\n
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12<\/div>\n<\/div>\n<\/td>\n
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Pressure chamber in<\/div>\n<\/div>\n<\/td>\n
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lower part<\/div>\n<\/div>\n<\/td>\n
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nozzle body<\/div>\n<\/div>\n<\/td>\n
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Compression spring<\/div>\n<\/div>\n<\/td>\n
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Edge filter<\/div>\n<\/div>\n<\/td>\n
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7<\/div>\n<\/div>\n<\/td>\n
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Injection nozzle holder,<\/div>\n<\/div>\n<\/td>\n
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Cross hole<\/div>\n<\/div>\n<\/td>\n
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upper part<\/div>\n<\/div>\n<\/td>\n
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15<\/div>\n<\/div>\n<\/td>\n
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Center hole<\/div>\n<\/div>\n<\/td>\n
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Leak-off connection<\/div>\n<\/div>\n<\/td>\n
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5 Clean pressure chamber (5) in nozzle body using annular groove scraper.<\/div>\n<\/div>\n<\/td>\n
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Annular groove<\/div>\n<\/div>\n<\/td>\n
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Nozzle orifice<\/div>\n<\/div>\n<\/td>\n
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Nozzle body<\/div>\n<\/div>\n<\/td>\n
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Injection pin<\/div>\n<\/div>\n<\/td>\n
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Inlet port<\/div>\n<\/div>\n<\/td>\n
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Throttle pin<\/div>\n<\/div>\n<\/td>\n
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4<\/div>\n<\/div>\n<\/td>\n
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Needle valve<\/div>\n<\/div>\n<\/td>\n
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10<\/div>\n<\/div>\n<\/td>\n
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Needle seat<\/div>\n<\/div>\n<\/td>\n
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5<\/div>\n<\/div>\n<\/td>\n
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Pressure chamber<\/div>\n<\/div>\n<\/td>\n
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Thrust shoulder<\/div>\n<\/div>\n<\/td>\n
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6<\/div>\n<\/div>\n<\/td>\n
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Orifice of inlet ports in<\/div>\n<\/div>\n<\/td>\n
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Needle stem<\/div>\n<\/div>\n<\/td>\n
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pressure chamber<\/div>\n<\/div>\n<\/td>\n
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6 Clean nozzle needle seat in nozzle body with cleaning cutter. This job should be given special care, since usability of a nozzle depends to a high degree on a good nozzle needle seat.<\/div>\n
Do not apply excessive pressure with cleaning cutter.<\/div>\n
Clean center hole (15 in fig. item 4) with cleaning needle (0.13 mm dia. or 0.18 mm dia.).<\/div>\n<\/div>\n<\/td>\n
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07.1.8-137\/3 F3<\/div>\n<\/div>\n<\/td>\n
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7 Clean injection hole in nozzle orifice, using injection hole cleaner. As can be seen in the illustra\u00adtion, work from inside to outside <\/strong>and not vice versa (so that injection hole cleaner is guided correctly and not twisted).<\/div>\n<\/div>\n<\/td>\n
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8 Clean nozzle needle with brass brush.<\/div>\n<\/div>\n<\/td>\n
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Nozzle orifice<\/div>\n<\/div>\n<\/td>\n
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Inlet port<\/div>\n<\/div>\n<\/td>\n
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Throttle pin<\/div>\n<\/div>\n<\/td>\n
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4<\/div>\n<\/div>\n<\/td>\n
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Needle valve<\/div>\n<\/div>\n<\/td>\n
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10<\/div>\n<\/div>\n<\/td>\n
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Needle valve seat<\/div>\n<\/div>\n<\/td>\n
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5<\/div>\n<\/div>\n<\/td>\n
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Pressure chamber<\/div>\n<\/div>\n<\/td>\n
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11<\/div>\n<\/div>\n<\/td>\n
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Pressure shoulder<\/div>\n<\/div>\n<\/td>\n
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6<\/div>\n<\/div>\n<\/td>\n
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Orifice of inlet ports in<\/div>\n<\/div>\n<\/td>\n
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pressure chamber<\/div>\n<\/div>\n<\/td>\n
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Thrust pin<\/div>\n<\/div>\n<\/td>\n
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Checking the needle valve<\/strong><\/div>\n<\/div>\n<\/td>\n
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9 Subject to sight-check. Used nozzles are to be sight-checked after cleaning. Check needle valve for indented or rough seat, and also for worn or damaged injection pins. Exchange any nozzle that is damaged.<\/div>\n<\/div>\n<\/td>\n
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07.1.8-137\/4 F3<\/div>\n<\/div>\n<\/td>\n
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10 Carry out test for freedom of movement. To do so, immerse needle valve and nozzle body in filtered diesel fuel, inserting needle valve into nozzle body. Hold nozzle body vertically and draw needle valve out by about one third. It must be able to slide back into its seat under its own weight. Exchange injection nozzle if necessary.<\/div>\n<\/div>\n<\/td>\n
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Assembly<\/div>\n<\/div>\n<\/td>\n
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11 Introduce all parts into lower part (5) of injection nozzle in reverse order and screw on upper part (7). Be sure to fit thrust pin (4) on needle valve (1) at end showing hole.<\/div>\n<\/div>\n<\/td>\n
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12 Clamp upper part (7) of injection nozzle in vise and torque lower part (5) to 70-80 Nm.<\/div>\n<\/div>\n<\/td>\n
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07.1.8-137\/5 F3<\/div>\n<\/div>\n<\/td>\n
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Checking<\/strong><\/div>\n
13 Check injection nozzles for satisfactory jet, rattling sound, injection pressure and leakage (07.1-135).<\/div>\n<\/div>\n<\/td>\n
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107-20857<\/strong><\/div>\n<\/div>\n<\/td>\n
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Adjustment<\/strong><\/div>\n<\/div>\n<\/td>\n
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14 <\/strong>In order to obtain correct injection pressure setting, it may be necessary to insert or remove steel shims (10) between compression spring (6) and upper part (7) of injection nozzle.<\/div>\n
Inserting<\/strong>\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 = higher injection pressure<\/strong><\/div>\n
Removing = lower injection pressure<\/strong><\/div>\n
These shims are available in thicknesses of 1.0 to 1.8 mm, in steps of 0.05 to 0.05 mm. Increasing the preloading by 0.05 mm increases the injection pressure by about 3.0 bar positive.<\/div>\n<\/div>\n<\/td>\n
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07.1.8-137\/6 F3<\/div>\n<\/div>\n<\/td>\n
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    07.1\u2014137 Disassembly, cleaning, assembly and adjustment of injection nozzles Job no. of flat rates or standard texts and flat rates data 07-6750 or 6752.   Testing data, injection nozzles   Bosch designation   Injection pressure in bar positive * for new injection nozzles for old injection nozzles, min. DNOSD2402) DNO SD 2400   135-143 120   DNOSD 240\/3)   2> The difference between any two injection nozzles within one engine must not exceed 5 bar positive. ) Starting production code no. 928 or 041.. ) Starting November 1981 with center hole 0.20 mm dia. (formerly 0.15 mm dia.)   Tightening torques   Nm Injection nozzles, upper and lower parts   70-80 Special tools     Socket 27 mm, 1\/2″ drive 11004-6193 001 589 65 09 00   Cleaner 000 589 00 68 00   Conventional tools   Torque wrench 1\/2″ drive, 40-130 Nm   Tester EFEP 60 H e.g. Bosch, D-7000 Stuttgart, Order No. 0 681 200 502   Cleaning needles 0.13 mm dia. e.g. Bosch, D-7000 Stuttgart, Order No. KDEP 2900\/3   Cleaning needles 0.18 mm dia. e.g. Bosch, D-7000 Stuttgart Order No. KDEP 2900\/5   07.1.8-137\/1 F3       Note The engine is equipped with a center hole pintle nozzle which is distinguished from the standard pintle by a cross hole and a center hole (14 and 15) in the thrust pin. Moreover, a maintenance-free edge filter (13) is pressed into upper part (7) of the in\u00adjection nozzle holder.   1\u00a0 \u00a0 Needle valve 2\u00a0 \u00a0 Nozzle body 3\u00a0 \u00a0 Nozzle holder insert 4\u00a0 \u00a0 Thrust pin 5\u00a0 \u00a0 Injection nozzle holder, lower part 6\u00a0 \u00a0 Compression spring 7\u00a0 \u00a0 Injection nozzle holder, upper part 8\u00a0 \u00a0 Leak-off connection 9\u00a0 \u00a0 Fuel inlet 10\u00a0 \u00a0Steel shim 11\u00a0 \u00a0 Annular groove and inlet ports 12\u00a0 \u00a0 Pressure chamber in nozzle body 13\u00a0 \u00a0 Edge filter 14\u00a0 \u00a0 Cross hole 1 5\u00a0 \u00a0Center hole   Disassembly   1\u00a0 \u00a0 \u00a0 \u00a0 Clamp upper part (7) of injection holder in vise so that leak-off connections cannot be damaged. 2\u00a0 \u00a0 \u00a0 \u00a0 Using socket, release and unscrew lower part (5) of injection nozzle holder. 5 Injection nozzle holder, lower part 7 Injection nozzle holder, upper part   3 Remove steel shim (10), compression spring (6), thrust pin (4), nozzle holder insert (3) and nozzle body (2) together with needle valve (1). Attention: When disassembling nozzle, be sure to keep nozzle body, needle valve and all other parts in correct order.   07.1.8-137\/2 F3       Cleaning   4 Using brass brush, remove carbon deposits from end face of nozzle body (2), chiefly around nozzle orifice. Using surface plate, check nozzle holder insert (3) and nozzle body (2) for truth at both ends. 1 Needle valve 9 Fuel inlet 2 Nozzle body 10 Steel shim 3 Nozzle holder insert 11 Annular groove and 4 Thrust pin   inlet ports 5 Injection nozzle holder, 12 Pressure chamber in   lower part   nozzle body 6 Compression spring 13 Edge filter 7 Injection nozzle holder, 14 Cross hole   upper part 15 Center hole 8 Leak-off connection       5 Clean pressure chamber (5) in nozzle body using annular groove scraper. 1 Annular groove 7 Nozzle orifice 2 Nozzle body 8 Injection pin 3 Inlet port 9 Throttle pin 4 Needle valve 10 Needle seat 5 Pressure chamber 11 Thrust shoulder 6 Orifice of inlet ports in 12 Needle stem   pressure chamber 13 Thrust pin   6 Clean nozzle needle seat in nozzle body with cleaning cutter. This job should be given special care, since usability of a nozzle depends to a high degree on a good nozzle needle seat. Do not apply excessive pressure with cleaning cutter. Clean center hole (15 in fig. item 4) with cleaning needle (0.13 mm dia. or 0.18 mm dia.).   07.1.8-137\/3 F3       7 Clean injection hole in nozzle orifice, using injection hole cleaner. As can be seen in the illustra\u00adtion, work from inside to outside and not vice versa (so that injection hole cleaner is guided correctly and not twisted).   8 Clean nozzle needle with brass brush.   1 Annular groove 7 Nozzle orifice 2 Nozzle body 8 Injection pin 3 Inlet port 9 Throttle pin 4 Needle valve 10 Needle valve seat 5 Pressure chamber 11 Pressure shoulder 6 Orifice of inlet ports in 12 Needle stem   pressure chamber 13 Thrust pin   Checking the needle valve   9 Subject to sight-check. Used nozzles are to be sight-checked after cleaning. Check needle valve for indented or rough seat, and also for worn or damaged injection pins. Exchange any nozzle that is damaged.   07.1.8-137\/4 F3       10 Carry out test for freedom of movement. To do so, immerse needle valve and nozzle body in filtered diesel fuel, inserting needle valve into nozzle body. Hold nozzle body vertically and draw needle valve out by about one third. It must be able to slide back into its seat under its own weight. Exchange injection nozzle if necessary.   Assembly 11 Introduce all parts into lower part (5) of injection nozzle in reverse order and screw on upper part (7). Be sure to fit thrust pin (4) on needle valve (1) at end showing hole.   12 Clamp upper part (7) of injection nozzle in vise and torque lower part (5) to 70-80 Nm.     07.1.8-137\/5 F3       Checking 13 Check injection nozzles for satisfactory jet, rattling sound, injection pressure and leakage (07.1-135). 107-20857   Adjustment 14 In order to obtain correct injection pressure setting, it may be necessary to insert or remove steel shims (10) between compression spring (6) and upper part (7) of injection nozzle. Inserting\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 = higher injection pressure Removing = lower injection pressure These shims are available in thicknesses of 1.0 to 1.8 mm, in steps of 0.05 to 0.05 mm. Increasing the preloading by 0.05 mm increases the injection pressure by about 3.0 bar positive.   07.1.8-137\/6 F3        <\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_crdt_document":"","footnotes":""},"categories":[49,44],"tags":[],"class_list":["post-2923","post","type-post","status-publish","format-standard","hentry","category-injection-system","category-om617"],"aioseo_notices":[],"featured_image_src":null,"author_info":{"display_name":"mackuz","author_link":"https:\/\/mbci.mackuz.ovh\/index.php\/author\/mackuz\/"},"_links":{"self":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2923","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/comments?post=2923"}],"version-history":[{"count":1,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2923\/revisions"}],"predecessor-version":[{"id":2924,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2923\/revisions\/2924"}],"wp:attachment":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/media?parent=2923"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/categories?post=2923"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/tags?post=2923"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}