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CRM-100
Common Rail Injector Repair Tool Sets
Instruction Manual

DENSO X2 Injectors

INJECTRONI CO., LTD.

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CRM-100 Common Rail Injector Measurement System
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1. Solenoid
2. Calibration shim, B**，
ID20mm, OD23.2mm,
Thickness 2.98-3.10mm
3. Armature
4. Ball
5. Nut
6. Valve spacer
7. Spacer
8. Dowel
9. Valve plunger
10. O-ring
11. Injector body
12. Spacer
13. Calibration shim, B23, ID
3.15mm, OD 5.75mm,
thickness 1.0-2.5mm
14. Spring
15. Pin
16. Dowel
17. Spacer
18. Dowel
19. Nozzle
20. Nozzle nut
21. Plastic cap

To measure total 2 calibration shims

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CRM-100 Common Rail Injector Measurement System
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Working Procedure – on Nozzle Side

Task 1 – Adjust Needle Opening Pressure (1)

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

Loose nozzle nut (20)

2. Remove Calibration shim B23 (13), spring (14), spacer

(12).

3. Install micrometer with extension probe 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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CRM-100 Common Rail Injector Measurement System
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Working Procedure – on Nozzle Side

Task 1 – Adjust Needle Opening Pressure (2)

4. Measure the thickness of shim B23 (13).

5. Fasten injector by using the matching holder on

frame 970100.

6. Place spacer(12) and shim B23 (13) in injector cavity.

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CRM-100 Common Rail Injector Measurement System
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Working Procedure – on Nozzle Side

Task 1 – Adjust Needle Opening Pressure (3)

7. Place 10mm thickness gauge on the injector.

Adjusting the position of micrometer. Zero
micrometer on the thickness gauge.

8. Remove the thickness gauge. Place spring(14) and

spacer (15) in injector

9. Place 10mm thickness gauge on it. Measure the top

of thickness gauge.

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CRM-100 Common Rail Injector Measurement System
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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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CRM-100 Common Rail Injector Measurement System
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Working Procedure – Solenoid Side

Task 2 – Inspect Weariness of Valve Spacer (1)

1. Loose solenoid (1) from injector.

2. Remove calibration shim B44（2), armature(3), and

ball(4)

3. Loose nut (5) by using special tool.

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CRM-100 Common Rail Injector Measurement System
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Working Procedure – Solenoid Side

Task 2 – Inspect Weariness of Valve Spacer (2)

4. Remove valve spacer (6). Check the sealing

surface in the center by using the microscope

5. The valve spacer with light weariness is still

usable. Replace the severe worn one with new

part.

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CRM-100 Common Rail Injector Measurement System
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Working Procedure – Solenoid Side

Task 2 – Inspect Weariness of Valve Spacer (3)

6. Place The ball (4), with flat surface up, on the

cavity at the end cavity of armature (3 ).

7. It is wrong to place the ball with spherical surface

up.

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CRM-100 Common Rail Injector Measurement System
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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 B44

3. Install injector on the frame 970100 by using

respective holder.

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CRM-100 Common Rail Injector Measurement System
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Working Procedure – Solenoid Side

Task 3 – Adjust Armature Lift (2)

4. Extension rod 511011 and sleeve 97039 on

micrometer.

5. Place calibration shim B44 (2) on injector

6. Place 1mm thickness gauge 511015 on shim B44

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CRM-100 Common Rail Injector Measurement System
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Working Procedure – Solenoid Side

Task 3 – Adjust Armature Lift (3)

7. Zero micrometer on the thickness gauge

8. Remove the thickness gauge and then measure

injector

9. If the measured value does not meet requirement,

replace calibration shim B44 with thickness

indicated on PC screen..

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CRM-100 Common Rail Injector Measurement System
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Working Procedure – Solenoid Side

Task 3 – Adjust Armature Lift (4)

10. Using the shim B44 of correct thickness to assemble

the injector. Fasten solenoid, torque 12-15Nm

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CRM-100 Common Rail Injector Measurement System