ANADOLU OTOMOTIV

NEEDS TO REPLACE THE VALVE FOR BOSCH UNIT INJECTOR AND UNIT PUMP

1. Bosch Type Unit Injector Or Unit Pump.

2. Indicator.

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3. Micrometer.

4. The indicator apparatus of diesel 5. The indicator apparatus of diesel

feeding gap for unit injector. feeding gap for unit pump.

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6. The indıcator apparatus of magnet gap for unit injector and unit pump.

7. Honing apparatus.

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8. Coarse type lapping apparatus for 9 Finish type lapping apparatus for
conical valve seat. conical valve seat.

10. Diamond lapping paste (3 micron – 3 STD)

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11. Wrench for maunting and 12. Allen for indicator.

dismaunting.

13. Mıcroscope.

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14. Wrench for dismounting magnet plate 15. Tork Allen.

16. CADdb Oversized Valves

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HOW TO CHANGE THE UNIT INJECTOR AND UNIT PUMP VALVE ?

1. Remove the unit injector totally and pick the used valve.

2. Measure the older valve taken from the Unit Injector by the micrometer.

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3. Find a new suitable valve taken from the measure of the older valve. For instance if the
older valve was 7.015 mm, test a 7.020 mm valve. If it is not suitable then test a 7.025 mm
valve. Here what’s important is to find the “transitional fitting valve”. And after honing
process it will slightly fitting valve.

Then begins the honing and lapping stage.

4. There are 2 lapping apparatus and 1 honing apparatus.

(1) Honing apparatus for hole.
(2) To restore conic angle as nonused state. (Lapping apparatus red)
(3) Surface finishing for disangle (Lapping apparatus green)

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OPERATING THE HONING PROCEDURE STEP BY STEP

5. Previously we found the suitable valve. (i.e 7.020 mm) Now we are going to set the
honning apparatus to 7.020 mm.

a) Extend the cylinder of honning apparatus to 7.020 mm by using hammer, if

body is smaller then the valve .

b) Otherwise turn the nut when honing apparatus is fixed for tightening the
diameter of honing cylinder. if body is bigger then the valve .

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6. After setting the honing apparatus with suitable measure we paste the
diamond abrasive.

7. Now we start honing to adapt the new valve to the valve hole. We revolve the
honing apparatus “on the top”. This takes 15-20 seconds. Here it’s important to wear
hole for slightly fitting valve.

İMPORTANT: To understand if honing does the extending, it’s necessary to get out
the honing apparatus seat below totally as it’s shown on the picture.

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8. Then we get the red pointed conic apparatus that satisfies us to restore the valve
seat. We also enlarge & diminish the red pointed conic in order to take the correct
diameter of hole just as the honing apparatus we mentioned above. We fix the red
pointed conic to the hole. If it hangs, there’s gap. Therefore we fix the seat to the tip and
hammer it. But if it doesn’t fix the hole any, then it means it’s big. So we lessen it.

9. After the right measure we better the angle with the red pointed conic apparatus. We
spin the conic apparatus back and forth “on the top” slightly. This taken 15-20 seconds.

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10. Do the same directions just as we mentioned above (9 & 10) with lapping tool green
pointed.

11. After finding the correct measure in order to better the surface quality, diamond
abrasive is pasted the part of the green pointed conic finish apparatus as it is seen
on the picture. By pressing slightly “on the top” of the green pointed finish apparatus
we spin it back & forth. This takes 15-20 seconds.

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12. We test the correct valve we tried before.

13. Then we paste the diamond abrasive on conic side of the valve.

14. We set the posted valve info the honing hole with allen wrench and make a mark by
pressing slightly (turn right & left)

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15. This mark must be a line and a complete circle.

16. Fix the indicator apparatus.

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17. By reversing the unit injector, we press the valve by touching then fix the indicator on
the top; Then set the indicator to zero.

18. Reversing the Unit Injector (the extend side) we press the stopper with tork wrench.

IMPORTANT: Constructing the stopper, tork wrench should be set to 55 N.meter

(BOSCH directive)

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19. After constricting the stopper, reverse the Unit Injector and place the indicator we
reset before s it’s seen on the picture. The reseted indicator should be 0,14 mm which
means diesel feeding GAP should be 0,14 mm (In some trucks it can be 0,15 mm)

IMPORTANT: If the diesel feeding GAP measures low (i.e. 0,11mm – 0,12mm) then
we sand the valve’s extend side slightly or sand the stopper. (Consideriny this
condition, our firm does the valves over-size 0,05 mm thicker.)

IMPORTANT: But if the diesel feeding GAP measures high (i.e. 0,16 mm – 0,17 mm)
then it’s necessary to rotate the stopper with tork wrench. It’s not suggested anyway
some make it effectively.

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IT’S TURN TO MEASURE THE MAGNET PART.

20. After roteting the stopper with tork wrench to 55 N.Meter we reverse the Unit Injector.
We tighten up the screws without spring.

21. There must be a gap as 0,25 mm. Between plate and housing of plate.

IMPORTANT: If it’s 0,30 mm instead of 0,25 mm. It pressures high level; İf it’s 0,30 instead of
0,25 mm. It pressures low.

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If it measures 0,25 mm instead of 0,20 mm. What should we do??

In this case we should sand this square plate 0,05 mm.

If it measure 0,30 mm instead of 0,25 mm. What should we do?

This time we should sand the housing of plate 0,05mm.

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22. After that we start to mount the Unit Injector.

23. After mounting we do the measure control by using selenoid multimeter. Selenoid
measure should be more or less 1,2 kb.

24. The Unit Injector is ready.

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25. If you have a test equipment, You can see that the valves work smoothly.

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