Bosch 110 Solenoid Cap Wrench | 2‑Pin Notch Driver With Depth Stop & Bi‑Directional Torque Ring

The Bosch 110 series common rail injector (CRI 110) uses a solenoid cap-a large hollow locknut with a distinctive multi‑notch pattern-to retain the electromagnetic coil assembly within the injector body. This cap must be tightened to a precise torque of 35–40 Nm to maintain the magnetic air gap between the armature and the coil pole. A cap that is not fully seated will allow the armature to move axially by as little as 0.03 mm, altering the solenoid's pull‑in force and shifting the injection quantity by 3–4 mm³/stroke. However, the greatest service challenge is not the torque specification; it is the fact that the cap's notches are often clogged with carbonized fuel residue and are recessed 6 mm below the solenoid housing's top face. Standard pin wrenches-with their rounded pins and lack of depth control-slip out of the notches under load, rounding the notch edges and rendering the cap unserviceable. The Bosch 110 Solenoid Cap Wrench (Model SCW-110) is a dedicated 2‑pin notch driver with a machined depth stop that ensures full‑depth pin engagement, preventing slipping and eliminating notch damage.

The Bosch 110 solenoid cap is secured by a circular collar with two diametrically opposed notches (or holes, depending on the revision). The wrench features two hardened steel drive pins that are precisely ground to match the notch profile:

Pin Diameter: 3.0 mm (matching the standard notch width on Bosch 110 caps).

Pin Length: 8.0 mm, extending from the tool face to the pin tip.

Pin Spacing: 26 mm center‑to‑center (matching the cap's notch spacing).

The pins are not cylindrical-they are slightly tapered (1° per side) to create a wedging action when the wrench is seated, ensuring that the pins contact the notch walls over their full length, not just at the tip.

The most common failure with generic pin wrenches is that the pins do not fully engage the notches because the tool bottoms out on the solenoid housing before the pins reach the notch base. This partial engagement causes the pins to slip under torque, damaging the notch edges. Our wrench incorporates a machined depth stop-a flat, ground shoulder on the tool's underside that contacts the solenoid housing's top face, setting the correct pin insertion depth of 6.0 mm. This depth stop ensures that the pins are always inserted to the same depth, regardless of variations in the operator's technique.

Depth Stop Diameter: 34 mm, clearing the solenoid housing.

Pin Engagement: 6.0 mm ± 0.2 mm (the cap's notch depth is 7.0 mm).

The solenoid cap often becomes seized due to thermal cycling and fuel residue adhesion. Applying a standard counter‑clockwise torque to break it loose can lead to pin slip. The wrench is designed with a bi‑directional torque ring-a reinforced section at the base of the pins that distributes the applied torque evenly between the two pins, eliminating the "leading pin" overload that causes one pin to slip before the other engages. This torque ring also provides a visual indicator: a red mark on the ring aligns with the torque direction, helping the operator maintain consistent force.

The wrench is fitted with a 1/2" square drive for use with a torque wrench or breaker bar. The drive is machined into the tool's central shaft, not into a handle, allowing the operator to choose the appropriate handle length for the application-short for clearance, long for leverage.

Q1: I have a Bosch 110 injector with holes in the solenoid cap, not notches. Will this wrench fit?
A: The wrench is designed for the notched cap, which is the standard for the Bosch 110 series. Some early production runs used a hole‑type cap; for those, we offer the SCW‑110H with pin tips sized for holes.

Q2: The depth stop seems to rest on the solenoid housing. Could it scratch the housing?
A: The depth stop has a ground, smooth surface (Ra 0.8 µm) and is made of steel that is softer than the solenoid housing. It will not scratch the housing, but we recommend cleaning the housing face before using the wrench to prevent debris from being trapped under the stop.

Q3: What is the specified torque for the solenoid cap?
A: Bosch specifies 35–40 Nm for the 110 series solenoid cap. Our wrench is rated for 50 Nm max, providing a safety margin for breaking free seized caps.

Q4: Can I use this wrench on other Bosch injectors, like the 120 series?
A: The Bosch 120 series uses a different cap diameter and notch spacing. This wrench is specific to the 110 series. We offer a separate model (SCW‑120) for the 120 series.

Q5: The pins are tapered-does that mean they will wear out faster than straight pins?
A: No. The taper creates a wedging action that distributes the load across the pin's full length, actually reducing the stress concentration at the pin tip. This prolongs pin life compared to straight pins that contact only at the tip.

Q6: The red mark on the torque ring seems purely cosmetic. Is it?
A: No. The red mark serves as an alignment aid for the operator-it indicates the primary torque direction (counter‑clockwise for removal, clockwise for installation) to ensure consistent pin loading across both pins.

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