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Testing and repair_cri Testing and repair_cri Presentation Transcript

  • 1 Testing and Repair of CRI and CRINTesting and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Preliminary testing and repair instruction for solenoid controlled Bosch Common Rail Injectors of the 1st and 2nd generation AA/PDS1 03.2004
  • 2 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Clean Workshop Area Automotive Aftermarket Any repair work on injectors is to be carried out on work- benches with stainless steel plating according to Bosch guidelines. Other workbench concepts do not meet the cleanliness demands for repair work on today´s modern Diesel com- ponents!
  • 3 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket General Subjects Bosch Common Rail injectors may only be repaired: • After any warranty period of the vehicle or engine has expired • Outside any in-field compliance periods required by law during which vehicles can be subject to exhaust tests. For an EURO3 vehicle this means three years and < 80.000 km, 5 years and 100.000 km for an EURO 4 vehicle. • Country specific rules and laws are to be obeyed. Testing of injectors on released test equipment is permitted at any time.
  • 4 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Special Features This instruction describes the testing and repair of solenoid controlled Common Rail injectors (CRI or CRIN, resp.) of the 1st and 2nd generation. Part numbers are 0 445 110 xxx (CRI) and 0 445 120 xxx (CRIN) These injectors are refered to as CRI1 and CRI2 or CRIN1 and CRIN2, respectively. The nozzle change on any CRI or CRIN can only be performed once in the livecycle of the injector. CRI1 Locating pins are used for aligning the nozzle to the injector body. Some CRI1 are using spiral type locating pins which can not be removed from the injector body. Injectors with this feature can not be repaired because the locating pins may break when mounting the nozzle retaining nut. When this happens, the alignment between nozzle and the fuel supply bore of the injector body is no longer given.
  • 5 Testing and Repair of CRI and CRIN Special features (Continued) CRI1 Injectors of this generation with cylinder-type locating pins can be repaired. The locating pins are to be replaced with new ones. Differences: Types with big pressure pin (top picture) or nozzle guided valve piston (DGV, picture below). The big pressure pin or the DGV-sleeve with a small pressure pin (pill) can not be replaced. These parts, like the nozzle spring and the adjustment shims, can be used again. CRI2 Like CRI1, but no types with big pressure pin, only DGV. Locating pins are always of the cylindrical type. AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket
  • 6 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Arrows on top picture: CRI with spiral-type locating pins, nozzle change not possible. Arrows on bottom picture: CRI with cylinder-type locating pins, nozzle change possible..
  • 7 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Special features (Continued) CRI1 and CRI2 The repair depth is limited to a nozzle change. A leak at the high pressure connection can be repaired by replacing both connection and seal.. This is not feasible for injectors that feature secured threads (Daimler- Chrysler vehicles). Injectors with this feature must be replaced with exchange- or new units when a leak occurs at the high pressure connection. Repair of any other leaks at injector connections or on the injector body is not possible. Repairwork that requires removal of the solenoid retaining nut is also not permitted.
  • 8 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Special features (Continued) CRIN Types CRIN1 or 2, Type 1, Standard Type for medium duty and heavy duty applications 1 = internal high pressure connection 2 = internal return flow connection 3 = electrical screw-on connections Automotive Aftermarket 1 2 3
  • 9 Testing and Repair of CRI and CRIN Special features (Continued) CRIN Types CRIN1 or 2, Type 2, Standard Type for light duty and medium duty applications 1 = external high pressure connection 2 = external return flow connection 3 = electrical plug-on connection CRIN1 or 2, Type 3, Special Type for light-, medium- and heavy duty applications 1 = external high pressure connection 2 = external return flow connection 3 = electrical screw-on connections 1 2 3 1 2 3 AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket
  • 10 Testing and Repair of CRI and CRIN Special features (Continued) CRIN Types CRIN1 or 2, Type 4, Special Type for light-, medium- and heavy duty applications 1 = external high pressure connection 2 = internal return-flow connection 3 = electrical screw-on connections 1 3 AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket 2
  • 11 Testing and Repair of CRI and CRIN Special features (Continued) CRIN1 The locating pins are to be replaced with new ones. Differences: Types with big pressure pin (top picture) or nozzle guided valve piston (DGV, picture below). The big pressure pin or the DGV-sleeve with a small pressure pin (pill) can not be replaced. These parts, like the nozzle spring and the adjustment shims, can be used again. CRIN2 Like CRI1, but no types with big pressure pin, only DGV. AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket
  • 12 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Special features (Continued) CRIN1 und 2 The repair depth is limited to a nozzle change. A leak at the high pressure connection can be repaired by replacing the high pressure fitting. This is not feasible for injectors that feature permanently fixed high pressure fittings. Injectors with this feature must be replaced with exchange- or new units when a leak occurs at the high pressure connection. Repair of any other leaks at injector connections or on the injector body is not possible. Repair work that requires removal of the solenoid valve retaining nut is also not permitted. Bild Permanentfi xierung Automotive Aftermarket
  • 13 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Visual Inspection • Check injector for corrosion and mechanical damage. • Damaged or incomplete injectors can not be repaired. • Injectors with strong corrosion or damaged electrical connections can not be repaired. • See pictures on the next pages.
  • 14 Testing and Repair of CRI and CRIN Lightly soiled/coked injector, repair possible Medium soiled/coked injector, repair still possible AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Strongly soiled/coked injector, repair not possible Automotive Aftermarket
  • 15 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Visual Inspection (Continued) Many injector types feature a guiding surface that aligns the injector properly at its mounting position inside the cylinder head, see picture below, item 1. A separate visual inspection is necessary. After testing and repair, mount the injectors to the same engine cylinders where they originally came from.
  • 16 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Guiding sleeve is in good condition, injector repair possible . Traces of wear on the guiding sleeve, injector can still be repaired. Automotive Aftermarket Guiding sleeve shows significant wear. Injector repair still possible, check age and mileage of the vehicle. Visual Inspection Of Guiding Sleeve
  • 17 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Removal of Coarse Dirt • Plug injector high-pressure and return flow connections as well as injector nozzle with plastic caps, check ESI[tronic] spare parts listings. • Remove coarse dirt and clean injector with cleaning detergent. Particularly the nozzle must not be cleaned with a wire brush • Avoid spilling cleaning detergent on the electrical connectors. • Dry the injector with clean compressed air and remove plastic caps when injector is dry.
  • 18 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Testing the Injector(s) • Mount the cleaned injector(s) on the test bench. • Run the cleaning/bleeding routine. • Determine the condition of the injector(s) according to the test results.
  • 19 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Leak Test Leaks at the high pressure connection: Replace connection and seal with new ones. This is not possible on Daimler-Chrysler vehicles because of the secured threads. Some CRIN types feature a permanently fixed high pressure connection, in this case, repair is not possible . See chapter „Nozzle Replacement“ for leaks at the nozzle retaining nut. Injectors with cracked housings, leaking return flow connections or leaks at the solenoid valve retaining nut can not be repaired. Replace with Bx-unit or new injector.
  • 20 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket General Information This chapter describes the testing of Common Rail injectors for both, passenger cars (CRI) and commercial vehicles (CRIN). The Bosch injection test bench EPS 815 with KMA 802 or 822 together with the CRS 845 test set is to be used for the testing. The CR basic set 1 687 001 846 is used for testing up to six CRI at the same time. The additional set 1 687 001 599 is used for testing one CRIN at the time. The use of other test benches or retrofit kits may lead to wrong testing results. Test specifications for Bosch injectors are published on the TestData CD-ROM. A valid subscription and access code are pre-requisites for using the CD. For additional information, consult ESI[tronic] Hotline. In general, the test sequences of CRI and CRIN are identical. Depending on the injector generation, e.g. CRI 1 or CRIN2, or differences like coded injectors, IMA , multi injection (MI), the number of test steps may vary.
  • 21 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Injectors of Competitors It is possible to use the EPS 815 test bench with KMA and the necessary CRI/CRIN test sets for testing injectors from other manufacturers. However, this is within the responsibility of the test bench operator. The Robert Bosch GmbH does not produce or submit any test data or specifications for injectors of other manufacturers. Prior to testing, perform measurements on vehicles with corresponding injectors in order to determine injector current flow and voltages, thus preventing any damage of the electronics of the test bench.
  • 22 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Basic Set for CRI Testing (1 687 001 846)
  • 23 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Additional Set for CRIN Testing (1 687 001 599)
  • 24 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket • Passenger car injectors (CRI) can be tested as a complete set. • Commercial vehicle injectors can only be tested individually, i.e. one at the time. • Use only undamaged high pressure test lines. • Only the CP 3.3 that comes with the basic test set is to be used as the high pressure supply unit. • When not in use, all hydraulical connections of the pump have to be sealed with the attached plastic plugs.
  • 25 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket • During the setup of the CRI/CRIN test set the CRS 845 rail pressure sensor has to be calibrated! Test bench pressure value low high External pressure value Prior to new calibration, clear old values first! DD.MM.YYYY Actual value in calibration mode! Save with F12 >>
  • 26 Testing and Repair of CRI and CRIN Injector AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. seal ring valve seal pliers Automotive Aftermarket Picture: Removal of the seal ring with commercially available pliers for valve seals, e.g. Hazet 791-5 Remove the seal ring using the pliers for valve seals. To do so, hold the seal ring with the pliers and pull it from the nozzle with slight turning motions. After a successful testing of the injector, put a new seal ring on the nozzle shaft and push it into the direction of the nozzle retaining nut.
  • 27 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Preparing the testing with EPS 815 • Clean the injector around nozzle and nozzle retaining nut. Use a nylon brush for removal of coarse dirt. Wash the cleaned surfaces with cleaning detergent. After that, clean the area of nozzle and nozzle retaining nut in an ultrasonic cleaning bath. Make sure the injector(s) are hanging in a correct angle into the bath and secure them from falling and tumbling. Add cleaning detergent until the nozzle retaining nut is completely covered. • Take the injector(s) out of the ultrasonic bath after approx. 15 minutes and dry them with clean compressed air
  • 28 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Testing • Mount the injector(s) onto the test bench by using the appropriate electrical and hydraulical adaptors. Consult the test bench manual for further information. • Shut the doors of the test bench. • Start the test program, key in the part number and the manufacturing date of the injector. • In case of coded injectors or IMA/NIMA, respectively, fill in the injector code. • Select test mode, e.g. initial testing or testing after repair and confirm. • Automatic testing starts.
  • 29 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Test Steps • Leak Test Visual inspection of the entire injector for escaping test oil. Only the high pressure supply and the return flow lines are connected to the injector(s) in order to do perform this test step. Do not connect the injector(s) electrically. Leaks at the high pressure connection or nozzle retaining nut may be repaired by using new parts. The feasibility depends on the type of injector, see chapter „repair“ of this instruction. All other leaks, e.g. at the solenoid retaining nut can not be repaired. Substitute this injector with a Bx- or new part.
  • 30 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Injector Testing • Leak Test • Interchange Test Return flow measurement testing only, do not connect injector(s) electrically! Start test and perform a visual check for leaks. Return flow bars have to be displayed corresponding to the number of injectors that are connected. When this doesn´t happen, check your measuring channel selection as well as the connection of the KMA inlets. Make corrections as necessary .
  • 31 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Test Steps • Quantity Measurement Connect injection chambers and electrical wires to the injector(s). Pay attention to hydraulical and electrical matching. Injected quantities are measured on the „odd channels“ (1, 3, 5, 7, 9 and 11), return flow quantities are measured on the „even channels“ (2,4, 6, 8 and 10) Up to six CRI can be mounted to the test bench and tested simultaneously. CRIN are tested one at the time by using the appropriate high- and low pressure adaptors. Refer to test set operating instruction for more information.
  • 32 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Injector Testing • Quantity Measurement Connect injection chambers and electrical wires. Start Test, check again for leaks.
  • 33 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Test Sequence: • Return Flow Measurement A defective nozzle and/or defective valves and seals can cause a too high return flow quantity. • Do not continue testing injectors with these presumed defects, measuring results of the other injectors will be influenced. • Perform a nozzle change on the injectors that had to be excluded from the testing. See chapter „Nozzle Change“ for further details.
  • 34 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Test Sequence (Continued) • Quantity test points and return flow rates have to correspond with the matrix-chart on the next page. • If not, the injector can not be repaired and needs to be substituted with a Bx unit or a new injector. • A nozzle change can rectify the problem of a too high return flow rate of the injector. After the nozzle change, re-run the test of the injector. In case that the flow rate is still too high, the injector has a defect that can not be repaired in a service workshop. Substitute the injector with a Bx- or new unit.
  • 35 Testing and Repair of CRI and CRIN Injector Testing (Nozzle Change useful) Q-Testpoint Return Flow Nozzle Change X + Yes + + Yes + X Yes -/0 + Yes -/0 X Yes At least 1 Q-Testpoint within range. Combinations are possible AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket X = In Range, + = Too high, -/0 = Too low or zero
  • 36 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Trouble Shooting Chart • Q-Testpoint within range, return flow within range: Injector is good • Q-Testpoint within range, return flow too high: Nozzle Change • Q-Testpoint too high, return flow too high:: Nozzle change • Q-Testpoint too low and return flow too high: Nozzle change • Q-Testpoint too low and return flow within range: Nozzle change • Q-Testpoint to low and return flow too low: Injector defective Other Combinations of Q-Testpoint and return flow rate results are possible, so a nozzle change may be useful. Whenever a nozzle change was carried out, the injector has to be tested again. After a nozzle change all Q-Testpoint and return flow measuring results have to be within range, otherwise replace injector with a Bx or new unit.
  • 37 Testing and Repair of CRI and CRIN Mounting Device for CRI and CRIN (0 986 610 130) Protractors and Nut Adaptors Lever with Spring- package for applying nozzle Tie-Down Force Adjustment Screw for Tie-Down Force Lower Clamping Brackets for Injectors Height Adjustment upper Clamping Brackets Height Adjustment of Lever Clamping Bracket for Vice Mounting AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Shaft Automotive Aftermarket Adjustable Reference- mark
  • 38 Testing and Repair of CRI and CRIN Mounting Device for CRI and CRIN (0 986 610 130) Nozzle Replacement, Working Steps Mount the injector absolutely vertical into the mounting device: Loosely mount the key-surface of the injector into the lower clamping brackets of the mounting device. Attach, align and fasten the upper clamping bracket to the injector housing so that the injector is fixed exactly vertical in the mounting device. When this is done, fasten the lower clamping bracket. Verify that the injector is still mounted absolutely vertical. Repeat the procedure if necessary. 1 2 AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. 1 = Lower Clamping Brackets 2 = Upper Clamping Brackets 3 = Tie-Down Force Lever Automotive Aftermarket 3
  • 39 Testing and Repair of CRI and CRIN Mounting Device for CRI and CRIN (0 986 610 130) AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Nozzle Replacement, working steps (Continued) • Place a collecting tray underneath the injector to catch down falling parts • Place nut adaptor on nozzle retaining nut • Set and align lever for tie-down force. • Apply tie-down force: Injector is mounted vertically into the mounting device, both upper and lower clamping bracket are fastened. Place body-fit sleeve on nozzle tip. Automotive Aftermarket
  • 40 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Mounting Device for CRI and CRIN (0 986 610 130) Nozzle Replacement, working steps Turn the adjustment screw for the tie-down force until there is no gap between the two sleeves, see pictures, Note: It is not necessary to mount the protractor that can be seen on the left picture for this working step. Automotive Aftermarket
  • 41 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle Replacement, Working steps • Pre-set a torque wrench to 150 Nm • Unscrew the nozzle retaining nut with the torque wrench. • If the nozzle retaining nut can´t be loosened with < 150 Nm, then the injector must not be repaired. Reason: Sealing surfaces can be damaged. In case the torque rate is higher, replace injector with a bx-unit ir a new one. • Further unscrew the nozzle retaining nut by hand.
  • 42 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Nozzle Replacement, working steps • Cut back the tie-down force • Remove nozzle retaining nut • Remove nozzle, pay attention to eventually falling parts! • Visual check: Determine whether the nozzle locating pins are of the spiral- or cylindrical type. Note: Spiral type locating pins can´t be removed without applying great mounting forces, cylinder type locating pins can be pulled out without great force. • An injector with spiral type locating pins must not be repaired. Re-assemble the injector and replace it with a Bx unit or a new injector. Automotive Aftermarket
  • 43 Testing and Repair of CRI and CRIN Nozzle Replacement (Overview) • Top picture, CRI1 with pressure pin: Remove locating pins, pressure pin, nozzle spring and adjustment shim from the injector housing. • Bottom picture, CRI 1 or CRI2 with nozzle guided valve piston (DGV): Remove locating pins, pressure pin (pill), guide sleeve, nozzle spring and adjustment shim from the injector housing. Handle these parts with care since they, with the exception of the locating pins, have to be reused in the same injector where they came out of. • Clean the reusable parts and nozzle retaining nut thread of the partially disassembled injector in an ultrasonic bath. Mount the injector(s) into a self-made clamp and secure them from tumbling or falling into the ultrasonic bath and place the reusable parts into a suitable screen or strainer. Remove the injector(s) from the ultrasonic bath after 15 minutes, dry with clean compressed air. • Inspect the injectors nozzle retaining nut thread, nozzle sealing surface, and the housing bore for damage by using an illuminated magnifying glass. AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket
  • 44 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle Replacement • Remove locating pins, pressure pin/DGV, nozzle spring and adjustment shim. The nozzle, its retaining nut and the locating pins must not be reused, discard and substitute with new parts. Pressure pin/DGV, nozzle spring and adjustment shims are not available as spare parts. These parts have to be reused in the same injector where they came out of. • The injectors nozzle retaining nut thread has to be thoroughly cleaned in an ultrasonic bath. Mount the injector(s) into a self-made clamping device and dip them into the cleaning detergent for 15 minutes Make sure the injector(s) do not submerge. • Remove the injectors from the bath and dry them with clean compressed air. Select new locating pins, nozzle and retaining nut from the spare parts list. • Clean the sealing surfaces of both nozzle and injector in cir- cular movements with a vacuum pump.
  • 45 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle Replacement • Refer to the chapter „Visual Inspection“ for checking the metal surfaces of the injector body by using a lighted magnifying glass. • Injectors with damaged surfaces must not be repaired, substitute with Bx- or new units.
  • 46 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Soiled, corroded threads. Ultrasonic cleaning necessary. Clean, undamaged thread Automotive Aftermarket Visual inspection of retaining nut thread The retaining nut thread of the injector body must not be damaged or soiled. Damaged and/or soiled threads lead to a faulty mount of both nozzle and retaining nut. As a result, leak will occur.
  • 47 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Nozzle Sealing Surface Automotive Aftermarket Top right picture shows standard sealing surface in excellent condition, injector can be repaired. Bottom right picture shows damaged sealing surface. Injector can not be repaired.
  • 48 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Nozzle Sealing Surface Automotive Aftermarket Top right picture shows „Maltese Cross Type“ sealing surface in excellent condition. Bottom right picture shows damaged sealing surface. Injector can not be repaired. Compare pictures on previous, the sealing surface must not show any damages.
  • 49 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Nozzle Sealing Surface Top right picture shows „Butterfly Type“ sealing surface in excellent condition. Bottom right picture: The red coloured areas must not show any damages. Injectors with damages in this area can not be repaired. Automotive Aftermarket
  • 50 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Visual Inspection of Bore Hole The injectors bore hole must not show any damages or corrosion. Picture on top shows a bore hole in good condition. The picture below shows a corroded bore hole. The injector must not be repaired. Automotive Aftermarket
  • 51 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle Replacement • Mount the cleaned and dried injector vertically into the mounting device. • Place adjustment shim, spring, DGC-sleeve (if available) and pressure pin correctly into the injector body. Make sure to reuse exactly the parts that came from the injector that is now reassembled. • Insert new location pins into the injector housing. The diameter of the location pin borehole is slightly smaller than the one for the supply to the nozzle. • Mount one of the protractors to the new nozzle retaining nut. • Place the cleaned new nozzle on the injector body, make sure the fuel supply bore hole(s) align properly.
  • 52 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle replacement • Hold nozzle down by hand and turn new nozzle retaining nut with attached protractor down. • Place nut adaptor on nozzle retaining nut. • Apply tie-down force
  • 53 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle Replacement Mounting process of nozzle retaining nut (NRN) • Positioning: Using a torque wrench, fasten NRN with 5 Nm. • Pre-tightening: Continue tightening with specified torque rate. • Loosening: Turn NRN ccw by 120°. • Final tightening: Fasten NRN with 5 Nm. Set protractor to 0°. Continue to turn NRN clockwise with specified angle rate. An exceeded torque range indicates a stiff moving retaining nut thread. • Reduce tie-down force completely, take nut adaptor from NRN. • Take injector out of mounting device. • Test repaired injector(s) on the test bench.
  • 54 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle Replacement Torque- and angle rates CRI 1 Standard nozzle sealing surface, NRN-thread M 15 x 0,5 or M 17 x 0,75 Pre-tightening: 60 +/- 2 Nm Loosening: 120° Positioning: 5 Nm Final tightening: 66° + 5°, -1° (M 15 x 0,5) 46° +/- 3° (M 17 x 0,75) Torque range: 33...50 Nm (M 15 x 0,5) 36...54 Nm (M 17 x 0,75) Maltese Cross sealing surface, NRN-thread M 15 x 0,5 or M 17 x 0,75 Positioning: 5 Nm Pre-tightening: 60 +/- 2 Nm Loosening: 120° Positioning: 5 Nm Final tightening: 53° +/- 3° (M 15 x 0,5) 40° +/- 3° (M 17 x 0,75) Torque range: 26...38 Nm (M 15 x 0,5) 32...50 Nm (M 17 x 0,75)
  • 55 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle Replacement Torque- and angle rates CRI 2 Butterfly sealing surface, NRN-thread M 15 x 0,5 or M 17 x 0,75 Pre-tightening: 40 +/- 4 Nm (M 15 x 0,5) 45+/- 4 Nm (M 17 x 0,75) Loosening: 120° Positioning: 5 Nm Final tightening: 60° +/-3° (M 15 x 0,5) 44° +/- 3° (M 17 x 0,75) Torque range: 26...45 Nm (M 15 x 0,5) 35...53 Nm (M 17 x 0,75) Butterfly sealing surface, only BMW, NRN-thread M 15 x 0,5 Pre-tightening: 40 +/- 2 Nm Loosening: 120° Positioning: 5 Nm 2nd pre-tightening: 73° +/- 3°, torque range 25...60 Nm Loosening: 90° Positioning: 5 Nm Final tightening: 60° +/- 3°, torque range 26...38 Nm
  • 56 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Tightening torque- and angle rates for CRIN (0 445 120 xxx) //DSM1Cummins0 445 120 018, 032 RL.N1DRST2DSM1RVI 0 445 120 012, 013, 016, 017 /DRST3DSM3Iveco0 445 120 011, 036 //DSM4RVI 0 445 120 009, 010, 014, 015, 019, 020 /DRST2DSM4Duramax0 445 120 008 //DSM1 Iveco/Cummins/ CNH 0 445 120 007 /DRST2DSM1MFTBC0 445 120 006 //DSM2RVI0 445 120 003, 004 /DRST1DSM1IVECO0 445 120 002 Return FittingHP-FittingRetaining NutVehicleInjektor No.
  • 57 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Tightening torque- and angle rates for CRIN (0 445 120 xxx) //DSM1Iveco0 445 120 028 //DSM1MAN 0 445 120 030, 031, 044, 045 /DRST3DSM3VolvoPenta 0 445 120 033 , 034, 051, 052 /DRST2DSM1Duramax0 445 120 027 //DSM1Ford Otosan0 445 120 025 Return FittingHP-FittingRetaining NutVehicleInjektor No.
  • 58 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle Replacement Torque- and angle rates CRIN with nozzle retaining nut (NRN) type DSM 1and 2 DSM 1 (NRN-thread M 19 x 0,75) Pre-tightening: 55 Nm (50...90 Nm) Loosening: 95° (85...95°) Positioning: 5 Nm Final tightening: 45° (43...47°) with max. torque rate of 70Nm DSM 2 (NRN-thread M 19 x 0,75, chamfered nozzle) Pre-tightening: 55 Nm (50...60 Nm) Loosening: 90° (85...95°) Positioning: 5 Nm Final tightening: 45° (43...47°) with max. torque rate of 80 Nm
  • 59 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Nozzle Replacement Torque- and angle rates CRIN with nozzle retaining nut (NRN) type DSM 3 and 4 DSM 3 (NRN-thread M 17 x 0,75) Pre-tightening: 55 Nm (50...60 Nm) Loosening: 90° (85...95°) Positioning: 5 Nm Final tightening: 45° (43...47°) with max. torque rate of 65 Nm DSM 4 (NRN-thread M 19 x 0,75) Pre-tightening: 55 Nm (50...90 Nm) Loosening: 90° (85...95°) Positioning: 5 Nm Final tightening: 40° (38...42°) with max. torque rate of 70 Nm
  • 60 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Injector Leaks Replacement of high pressure fitting: • Not possible with CRI/CRIN that feature secured threads (e.g. Daimler Chrysler). Refer to spare parts list! • Clean the injector around the high pressure fitting by using a vacuum pump. • Mount the injector into a vice by using a v-block, unscrew old fitting with a torque wrench. The loosening torque must not exceed 100 Nm. • Take old high pressure fitting out of the injector housing. • Remove sealing shim. Replacement of screwed-on return flow fitting on CRIN: • Not possible with permanently fixed return flow fitting! • Mount fitting into thread by hand. • Apply final torque rate of 2.5...3.5 Nm to the fitting
  • 61 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Visual Inspection High Pressure Fitting Automotive Aftermarket Damaged sealing surfaces can cause leaks. The used sealing shim may have small impression traces. Other damages, like burrs, are not tolerable because they can become loose and cause further damage to the injector. Note: Injectors for Daimler-Chrysler vehicles have secured threads, fittings can not be removed from the injector. Injectors for commercial vehicles (CRIN) do not have sealing shims for the high pressure fitting.
  • 62 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Top left picture: Thread in good condition Right pictures: Damaged threads, no injector repair possible. Replace with Bx-or new unit.
  • 63 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Left side pictures: Sealing surface for high pressure fitting in good condition. Picture below: Damaged sealing surface, injector can´t be repaired.
  • 64 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Tightening torque rates for high pressure fitting Working steps for CRI ( 0445 110 xxx) • Apply a thin coat of clean oil to the new fitting. • Mount the new fitting with a new sealing shim (CRI only). Tightening torque 40...44 Nm. • After repair, run injector leak test on test.
  • 65 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Tightening torque rates for high pressure fitting Working steps for CRIN ( 0445 120 xxx) Apply a thin coat of clean oil to the new fitting. Fitting for 6 mm high pressure tube (DRST 1 und 3) Pre-tightening: 50 Nm (45...55 Nm) Loosening: 90° (85...95°) Final tightening: 75 Nm (45...75 Nm) Angle control: 15° (13...17°), with max. torque rate of 70 Nm Fitting for 8 mm high pressure tube (DRST 2) Pre-tightening: 70 Nm (65...75 Nm) Loosening: 90° (85...95°) Final tightening: 93 Nm (60...93 Nm) Angle control: 20° (18...22°), with max. torque rate of 70 Nm
  • 66 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket After the repair work the injector(s) have to be tested dynamically on the test bench. In case the measured quantities are not within specification, the injector has a defect that can not be repaired in service. Use a new injector or a Bx-unit as a substitute. If all measurements are within specification, the injector can be remounted to the engine. As an indication for the repair work, scratch a cross onto the key surface of each injector by using a scribe.
  • 67 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket After completing the re-instalment, run the engine until it has reached operating temperature, check for leaks. Make another check for leaks after a test drive and perform an exhaust gas test.
  • 68 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Devices, Tools and auxiliary equipment • Mounting Device for CRI and CRIN 0 986 610 130 • Mounting Sleeves for CRIN O-Rings Set of four sleeves 0 985 612 930 30.8 x 150 mm 0 986 612 931 30.8 x 146 mm 0 986 612 932 29.3 x 150 mm 0 986 612 933 27,8 x 152 mm 0 986 612 934 • Torque Wrench, measuring range 0...25 Nm commercially available • Torque Wrench measuring range 25...100 Nm commercially available • Open-End bit 27 mm for torque wrench commercially available • Ultrasonic Cleaning Bath commercially available • Cleaning Detergent, e.g. Tickopur commercially available (Must contain ammonia, suitable for removal of corrosion and particulate matters) • Clamping Device for injectors self made • Commercially available mineral oil for mounting high pressure fittings, e.g. - Renolin MR 46 MC - Astron HVLP 46 - alternatively engine oil 5 W 40
  • 69 Testing and Repair of CRI and CRIN AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Automotive Aftermarket Abbreviations • DGV Nozzle Guided Valve Piston (Düsengeführter Ventilkolben) • DSM Nozzle Retaining Nut (Düsen Spannmutter) • IMA Injector Quantity Balancing for CRI (Injektor Mengen Abgleich) • NIMA Injector Quantity Balancing for CRIN (Nutzfahrzeug Injektor Mengenabgleich) • ISA Injector Voltage Balancing for CRI3 (Injektor Spannungs Abgleich) • CRI Common Rail Injector for Passenger Cars • CRI1, 2 Injector generations with typical features • CRI3 Common Rail injector with piezo actuator • CRS 845 Test set for testing Common-Rail high pressure pumps • CRIN Common Rail injector for commercial vehicles • CRIN1, 2 Injector generations for commercial vehicles with typical features • KMA Continuous Quantity Analysis (Kontinuierliche Mengen Analyse) KMA 802 with PC in test bench KMA 822 with PC in separate trolley • EPS 815 Injection test bench, base model