COMMERCIALLY CONFIDENTIAL

SMART INJECTOREQUIPMENT: Smart Injector for DAF MX and PR Engines

SUBJECT: Release of service solution for Smart Injectors fitted to DAFEuro4 engines.

1. INTRODUCTION

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

The repair solution consists of the following items:-

• Specialist tooling to enable the unit to be dismantled and re-assembled.

• A workshop manual detailing the recommended tooling and procedures required for asuccessful repair.

• The test equipment and data necessary to perfom unit overcheck and trim code generation.

• Parts lists and appropriate notes.

2. REPAIR TOOLING

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

Diesel InformationTECHNICAL June 2014

DT557(EN)

Delphi Diesel Systems Ltd, Diesel Aftermarket, Spartan Close, CV34 6AG, Warwick, England.Tel: [44] [0] 1926 472 900 Fax: [44] [0] 1926 472 901 © Delphi

Special Tooling - Kit YDT764 consisting of :-Mounting plate - YDT569 O-ring fitment tool (MX Body Upper) - YDT761Capnut tool - YDT703 O-ring fitment tool (MX Body Lower) - YDT762Air Leak test Tool - YDT760 A spare sealing washer for tool YDT760O-ring fitment tool (PR Body) - YDT763 Stator Contact Re-shaping Tool - YDT704Standard Tooling1/2" Drive Torque Wrench 0 - 180 Nm 20IP Torx Plus bit and Holder3/8" Drive Torque Wrench 0 - 30 Nm Brass Bristled Brush

Long nosed Pliers Careclean Fluid27 mm Socket Lint-free, non-flocking cloths3/8" Drive 6mm Hexagon bit and holder

3. WORKSHOP MANUAL

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

4. TEST PLAN AND TRIM CODE GENERATION

The test plans and trim code generation is contained within the latest release of IRIS software, theproduct licence is supplied within the DDQX122F licence package, which must be activated beforeany tests can be performed. A dedicated PDF help file is included within the IRIS software. Referto DT507/3 for information surrounding the angular calibration requirements for EUP & SmartInjector testing.

5. PARTS LISTS AND EXPLODED VIEW DIAGRAMS

These are available on the latest version of Direct Evolution.

6. TEST EQUIPMENT AND SOFTWARE

The equipment required to test the Smart Injectors is a development of that used to test the currentrange 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 SupplierTest Bench AVM20A-B HartridgeRack Enclosure Kit HK1500 HartridgeRack Dual Control Kit HK1501 HartridgeBase Cambox HK1502 Hartridge50V Dual Control Kit HK1511 HartridgeCR/EUI Interface kit HB418 HartridgeRouter HJ069/HJ070 Hartridge7 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 SupplierEUP/Smart Upgrade Base Kit HK1590 HartridgeDAF MX Injector Application Kit HK1591 HartridgeDAF PR Injector Application Kit HK1592 HartridgeIris Licence DDQX122F DelphiIris Software V1.017.01 or later DelphiDual Logic Cable AE103/6 Hartridge

HK1590 + HK1592 illustrated below.

In addition a standard EUP which is compatible with the injector being tested (and must be keptonly for injector testing) is required.

Refer to the workshop manual or the IRIS PDF help file for the correct installation procedure.

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