Diesel Information

TECHNICAL JUNE 2014

DT557(EN)
COMMERCIALLY CONFIDENTIAL

SMART INJECTOR
EQUIPMENT: Smart Injector for DAF MX and PR Engines

SUBJECT: Release of service solution for Smart Injectors fitted to DAF Euro4
engines.

1. INTRODUCTION

This note details the tooling, documentation, and test equipment required to service the range of
Smart injectors fitted to DAF engines for the Euro 4 emissions specifications.

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The repair solution consists of the following items:-

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• Specialist tooling to enable the unit to be dismantled and re-assembled.
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A workshop manual detailing the recommended tooling and procedures required for a
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successful repair.
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• The test equipment and data necessary to perform unit overcheck and trim code generation.
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• Parts lists and appropriate notes.

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2. REPAIR TOOLING
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The repair tooling consists of toolkit YDT764, which contains the items listed below, and a number
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of standard workshop tools.

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Delphi Diesel Systems Ltd, Delphi Diesel Aftermarket , Spartan Close, CV34
6ZQ, Warwick, England.
Tel: +44 (0) 1926 472 900 Fax: +44 (0) 1926 472 901 © Delphi
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Special Tooling - Kit YDT764 consisting of :-

Mounting plate - YDT569 O-ring fitment tool (MX Body Upper) - YDT761
Capnut tool - YDT703 O-ring fitment tool (MX Body Lower) - YDT762
Air Leak test Tool - YDT760 A spare sealing washer for tool YDT760
O-ring fitment tool (PR Body) - YDT763 Stator Contact Re-shaping Tool - YDT704
Standard Tooling
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2 Drive Torque Wrench 0 - 180 Nm 20IP Torx Plus bit and Holder
3/ "
8 Drive Torque Wrench 0 - 30 Nm Brass Bristled Brush
Long nosed Pliers Careclean Fluid
27 mm Socket Lint-free, non-flocking cloths
3/ " Drive 6mm Hexagon bit and holder
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3. WORKSHOP MANUAL

The manual detailing the necessary repair tooling, dismantling and re-assembly procedures, and
test equipment is available on Direct Evolution under publication number DDNX424.

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4. TEST PLAN AND TRIM CODE GENERATION
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The test plans and trim code generation is contained within the latest release of IRIS software, the
product licence is supplied within the DDQX122F licence package, which must be activated before
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any tests can be performed. A dedicated PDF help file is included within the IRIS software. Refer
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to DT507/3 for information about the angular calibration requirements for EUP & Smart Injector
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testing.
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5. PARTS LISTS AND EXPLODED VIEW DIAGRAMS

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These are available on the latest version of Direct Evolution.

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6. TEST EQUIPMENT AND SOFTWARE

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The equipment required to test the Smart Injectors is a development of that used to test the current
range of E3 Electronic Unit Injectors, with the addition of a number of upgrade kits.
Existing Test Equipment
Workshops upgrading their capability from EUI (E3) should already have the following equipment :-

Component Part Number Supplier

Test Bench AVM20A-B Hartridge
Rack Enclosure Kit HK1500 Hartridge
Rack Dual Control Kit HK1501 Hartridge
Base Cambox HK1502 Hartridge
50V Dual Control Kit HK1511 Hartridge
CR/EUI Interface kit HB418 Hartridge
Router HJ069/HJ070 Hartridge
7 bar Supply Pressure Kit HS237 Hartridge
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If not this will need to be purchased in addition to the items listed below.

New Test Equipment and Software

The following new test equipment is available for authorised testing of Delphi Smart injectors:-

Component Part Number Supplier

EUP/Smart Upgrade Base Kit HK1590 Hartridge
DAF MX Injector Application Kit HK1591 Hartridge
DAF PR Injector Application Kit HK1592 Hartridge
IRIS Licence DDQX122F Delphi
IRIS Software V1.017.01 or later Delphi
Dual Logic Cable AE103/6 Hartridge

HK1590 + HK1592 illustrated below.

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In addition a standard EUP which is compatible with the injector being tested (and must be kept
only for injector testing) is required.
Refer to the workshop manual or the IRIS PDF help file for the correct installation procedure.