DAF Injector Service Master Set – Complete Overhaul Kit With Holder Clamp, Torque Wrench & Dual Shim Boxes

Servicing a DAF common rail injector-whether from the MX-11, MX-13, or the earlier XE series-requires three distinct operations: securely holding the injector body during disassembly, precisely torquing the nozzle retaining nut, and adjusting the needle valve lift with accurately thickness-graded shims. In many workshops, these three operations are performed with an improvised bench vice, a generic torque wrench, and a random collection of shims stored in unlabelled bags-a combination that typically produces a 20–25% rework rate on the flow bench.

The DAF Injector Service Master Set consolidates these three essential tasks into a single, coordinated system: a dedicated holder clamp that secures the injector without distorting its body, a specialised torque wrench with a DAF-specific nozzle socket, and two shim boxes containing a comprehensive range of precision shims for needle lift adjustment. The set is purpose-designed for DAF common rail injectors used in PACCAR MX engines, reducing service time and improving first-pass yield.

Parameter	Generic Tools	DAF Injector Master Set	Improvement
Injector disassembly time	8 min	4 min	50% reduction
Torque scatter (nozzle nut)	±4.2 Nm	±1.4 Nm	67% reduction
Shim selection time	6 min	30 sec	92% reduction
Flow bench first-pass yield	68%	94%	+26%
Rework rate (post-service)	22%	5%	77% reduction

The set's coordinated design ensures that the injector is held in the correct position (holder clamp), torqued to the correct specification (torque wrench with DAF-specific socket), and shimmed with the correct thickness (precision shim boxes). Eliminating the "guesswork" in each operation results in a measurable increase in service quality.

The holder clamp is a precision-machined steel fixture that secures the DAF injector body during disassembly and reassembly. It is not a generic bench vice with soft jaws-it is a component-specific holder that engages the injector's locating flats, preventing rotation and eliminating the risk of distorting the injector body.

Specifications:

Material: AISI 4140 steel, black oxide finish

Clamping mechanism: Cam-operated lever (quick-release), 30° rotation locks/unlocks

Clamping force: 150 N (nominal) – sufficient to hold the injector securely without crushing it

Injector engagement: Two hardened steel locating pins (58 HRC) that fit the injector's flats, ensuring the correct rotational orientation

Base plate: 10mm thick steel with two mounting slots for bench clamping (M8 bolts)

The clamp is designed to hold the injector in a vertical position-the correct orientation for removing the nozzle retaining nut and accessing the needle spring assembly. The cam lever allows the injector to be secured or released in under 3 seconds.

The torque wrench is not a standard workshop torque wrench; it is a factory-calibrated, DAF-specific tool that includes the correct socket for the injector's nozzle retaining nut, pre-set to the torque value specified in the DAF service manual.

Specifications:

Torque range: 15–80 Nm (adjustable, but factory-set to 45 Nm for the nozzle nut)

Accuracy: ±1.5% of reading (ISO 6789 certified)

Drive: 1/4" square drive (standard)

Socket included: 24mm 12-point, thin-walled design – specifically machined to clear the injector nozzle body

Socket material: AISI 4130 steel, hardened to 48–52 HRC, black oxide finish

Length: 280mm (comfortable for hand operation with a clear view of the injector)

The socket is thin-walled to clear the injector's nozzle body without contacting it-a critical detail when the injector is held in the clamp, as a standard socket would contact the nozzle body and either scratch the surface or interfere with the torque reading.

Q: Can the holder clamp be used on injectors from other brands, such as MAN or Volvo?
A: The clamp is specifically machined for DAF injector body flats-it will not fit MAN or Volvo injectors, which have different locating geometries. However, the torque wrench and shim boxes are universal: the torque wrench can be used with a different socket, and the shims are compatible with other injectors that use a 12.0mm OD shim. The clamp is DAF-specific.

Q: The shim boxes contain two pieces of each thickness-why two, not one?
A: Injector overhaul typically involves six injectors (for a 6-cylinder engine). By providing two of each thickness, the set allows the technician to service up to two injectors with the same thickness without needing to reorder. For a complete engine overhaul (6 injectors), you would need three shims of the same thickness-but the requirement for a specific thickness varies between injectors, so the distribution of two per thickness covers the majority of service scenarios. Additional shims can be ordered separately.

Q: Does the torque wrench require calibration, and is a certificate supplied?
A: The torque wrench is factory-calibrated and supplied with a certificate showing readings at 20 Nm, 45 Nm, and 80 Nm. We recommend recalibration every 12 months or after 5,000 actuations. The kit includes a reminder card for the recalibration due date. We offer a recalibration service with a 5-working-day turnaround.

Q: The shim boxes are labelled "A" and "B"-how do I know which box to use for a specific engine?
A: The DAF service manual specifies the needle lift target. If the calculated shim thickness is ≤0.90mm, use Box A; if >0.90mm, use Box B. The boxes are stored together, and the label on each box clearly indicates the thickness range. For most DAF injectors, the typical shim thickness is 0.60–0.80mm-so Box A is used most frequently. Box B is for injectors with significant wear where a thicker shim is required.

Q: Can I use a standard 24mm socket instead of the supplied thin-walled socket?
A: The standard socket will physically fit the nozzle nut, but it may contact the injector body during tightening-especially when the injector is held in the clamp. The thin-walled socket is designed to clear the injector body, preventing side-loading that can cause the torque wrench to click prematurely. We recommend using the supplied socket for accurate torque application.

Q: Is the holder clamp suitable for use with a power driver, or should it be used manually?
A: The clamp is designed for manual use with a standard torque wrench. It is not designed for power driver applications-the clamping force is sufficient for manual operations, and the cam lever is not intended for repeated power-driven cycles. The set is a workshop service tool, not a production-line fixture.

 

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