Common Rail injectors Testing, dismantling, and now μ-precision repair
Common Rail injector repair : Opportunities for service centers 350 million
Common Rail sales figures injectors in Europe
Com.veh. (CRIN)
Cars (CRI)
1998
2001
2004
2007
2010
2013
2016
Trend Trend on the diesel market
Rapid developments in diesel technology
In order to provide diesel customers with professional,
Technical innovations are bringing change to the world
cost-effective repair solutions, it is becoming ever more
of diesel at an ever accelerating pace. The main drivers
vital for vehicle service centers to have expertise in the
of this trend are new legal requirements, more stringent
latest fuel injection systems.
emissions standards and also new system functionality, such as pre-injection.
CRI (Common Rail injectors for passenger cars) and CRIN (Common Rail injectors for commercial vehicles)
Bosch boosting diesel popularity
on the diesel service market
State-of-the-art State-of-the-art diesel systems from Bosch, featuring
Testing and replacement of injectors is becoming an ever
Common Rail high-pressure pumps and injectors, have
more vital part of diesel ser vice. Emissions are subject
not only set the standard for modern-day diesel vehicle
to increasingly tight controls. Engine performance and
performance. They have also made diesel more popular
fuel efficiency eff iciency have to be balanced. Consequently, CRI /
thanks to the fuel economy and smoother drive they
CRIN servicing is becoming a benchmark for customer
offer. Bosch has to date fitted more than 50 million
satisfaction.
diesel injection systems as original equipment worldwide. And that means an incredible total of over
Benefits from the complete injector ser vicing package:
350 million injectors.
What began in 2005 as merely a nozzle replacement service has since grown into a complete backup package.
Diesel success as a service opportunity
Immediately you can:
There are large numbers of diesel-powered diesel-powered vehicles on
Interchange Interchange all injector components
the roads, and so more and more vehicles with high-
Service all current Bosch solenoid-controlled
pressure injection systems are being brought into
injectors till – up to 1800 bar (CRI 1.0-2.2; CRIN 1-3)
service centers for diagnostics, testing and repair.
to factory standard
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Take on practically any repair job
Tools for complete repair of Common Rail injectors
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3
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Repair tools for Common Rail injectors in jectors
Assembly and measurement fixture
Complete tool set
The right tools for efficient repair
Assembly and measurement fixture
To ensure professional repair of Common Rail injectors
The data recordings by the digital dial gage and measure ment
for cars and commercial vehicles (CRI / CRIN) by ser vice
adapters are reliably and accurately saved to the service program.
centers, Bosch provides a set of precision tools specially tailored to the demands of modern-day diesel products.
Digital angle / torque wrench CRR 320 The unit's integrated database enables it to handle any
Digital dial gage CRR 420
tightening torques and angles, such as on measuring tools,
Bosch service equipment is subject to the same
nozzle retaining nuts and valve clamping screws. screws.
standards as are applied in injector manufacture. As one illustration, il lustration, the digital dial gage measures
Measurement adapters and calibration tools
to an accuracy of 1 / 1000 mm.
The package of measurement heads, adapters, calibration fittings and component fixtures enables all injector components to be precisely calibrated.
Digital dial gage with pneumatic damper 4
Measurement adapters and calibration tools
Digital angle / torque wrench
Pneumatic fitting tool
Armature stroke control unit CRR 220 /
Pneumatic fitting tool CRR 130
Pneumatic control unit CRR 120
Depending on the injector type, solenoid assemblies
A pneumatic control unit and defined application of
may be fitted with a stop sleeve. To remove and refit it,
measurement forces ensure reproducibility of measured
a defined force needs to be applied, with a short press
values and conformance to tolerances within the �m range.
time, activated by the pneumatic control unit CRR 120.
The repair software CRR 920
CRI / CRIN shims
For efficient calibration of functional parameters, parameters,
A wide range of options (shim graduations from
data recording and calculation of shim thicknesses
2 to 10 �m) are available for injector adjustment.
for the respective processing step.
The color coding simplifies finding the appropriate washer(s).
Armature stroke and pneumatic control units
Repair software
CRI / CRIN shims 5
The systematic approach to repair : Sequence outlined briefly
Dial gage, measurement adapter and angle /torque wrench
Armature stroke / pneumatics control unit measurement
Optimal repair sequence
Visual inspection (based inspection (based on fault illustration diagrams
The various individual steps must follow one another
from the service manual). If defective parts are
exactly for the repair:
identified, they are replaced.
Measurement "Armature stroke, electric"
For a time-saving receiving inspection
Measured value NOK, injector faulty
Calibration of functional parameters and parameters and step-bystep assembly of the injector.
Interim check: Electrical armature stroke measure-
Start of repair: Clean thoroughly in ultrasonic bath,
ment, ment, revealing possible assembly errors (e.g. valve
disassemble injector
ball forgotten).
Measured value OK Hydraulic test on test stand
Measured value OK, repair completed Test on the EPS 815 / EPS 708, determine code as necessary.
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Servicing systems systems delivering genuine benefit
The software indicates which shim is needed
Shim fitting
Repair software with user guidance CRR 920
Groundbreaking Groundbreaking full repair package
Simple sequencing of complex repair procedures
Software calculates required shim thickness for precision calibration without rework
Replacement of injector body, all component assemblies and single parts
Repair options for defects which were until now not repairable
Tightening torques and angles directly from a database
No need for time-consuming manual adjustment of torque and rotation angle disk.
Efficient servicing based on coordinated tooling and user guidance
Optimum injector setting based on use of specially graduated shims
Upgraded fitting tool No need for time - consuming switching to different fixture during assembly. assembly.
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Protecting investment : Reuse of repair tools
Injector fitting tool, stage 1
Case with special tools for stage 2
Previous repair stages still in operation
Stage 1: Nozzle replacement
Carrying out repairs to diesel components is nothing
Stage 1 of the CRI and CRIN repair package comprises comprises
new to you, and you have already invested in the first
the tool set for replacement of the diesel injector nozzles.
stages of the CRI /CRIN repair package. You can continue to use the stage 1 fixture for removal. The stage 2 fixture
Stage 2: Replacement of the high-pressure sealing ring
will serve in future as a fitting and measuring tool. This
The stage 2 procedure can also be applied to replace the
approach approach is a practical aid in attaining the essential
high-pressure ring on the Common Rail injector.
degree of cleanliness. The dismantling and assembly processes are strictly separated.
Stage 1: Nozzle replacement 8
Stage 2: Replacement of the high-pressure sealing ring
Cleanliness is essential to diesel repair 1
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4
3
5
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1 Washing station with component washing machine and ultrasonic cleaner 2 Airlock access for material 3 Airlock access for personnel with dust-binding mat 4 Dismantling station 5 Component washing station with Bekanol bath, ultrasonic cleaner (replacement parts) and drying trough 6 Assembly station 7 Parts store
A work bench for professionals
Practical layout of a ser vice area
Cleanliness, cleanliness, cleanliness!
Ultrasound bath: thorough cleaning
Cleanliness is vital when working on diesel equipment.
High-efficiency pressure jets from state-of-the-art state-of-the-art ultra-
The electrical and mechanical components of modern-
sonic systems ensure that all parts, par ts, including the fine
day diesel systems are subject to the highest quality
nozzle holes of the injectors, are cleaned without damage.
demands. That is true especially of high-pressure pumps
A work bench that assures top quality
and injectors in Common Rail systems. Even the tiniest
The diesel work bench is the essential basis for
contaminants can cause them to malfunction.
professional, professional, error-free repair of all diesel
Divided room concept
components, from conventional systems to state-of-
Spatial separation of the preliminary cleaning step out-
the-art diesel injection technology. technology. It may be fitted out
side the "closed room" from the disassembly, disassembly, cleaning
with different tool boards depending on the repair case.
of the individual parts and assembly steps inside the "closed room" is important. Appropriate furnishing of the work room optimizes these operations.
Cleaning in an ultrasonic bath
Everything exact: the workshop magnifier
State-of-the-art State-of-the-art diesel work bench 9
Bosch testing systems for Common Rail injectors in jectors
EPS 815: The professional test rig for diesel components
ESI[tronic] 2.0 software
Precision testing after full service
Precision is the key
The latest Bosch field service concept (designated “FIS”)
Common Rail injectors are high-tech components which will
for solenoid-controlled injectors now expands the
work properly only if they are kept within the tightest tole-
possibilities of diesel servicing even further. After
rances. That is demonstrated by the check using the EPS 815
servicing, the injection quantities of the injectors are
and the corresponding corresponding supplementary equipment sets.
tested in the tried and proven way.
Test kit for EPS 815 for the testing of Common Rail overview of components
EPS 815
CRS 845
Diesel
Common Rail
injection pump
pump
test rig
supplementary equipment set
Supplementary set CRI 846 H for cars
CRIN for comm. veh.
Supplementary set CRI / CRIN 848 H
CRI Delphi / Denso
Accessory set CP1
CRI Piezo
Accessory set CP2
CRI 2.5 (CRI 2-18, 2-20) Adapter set for new injector generation
Accessory set CP3
Accessory set CP4
Accessory set CB18
Accessory set CB28 Accessory set CP Delphi/Denso/Siemens 10
ESI[tronic] 2.0, training and hotline : Complete service support
Service training: the ideal tuition for the full range of repair procedures
ESI[tronic] 2.0: Software for diesel service
Technical hotline provided by the diesel specialists
The entire diesel testing and repair procedure is soft-
Saving you both time and money, the Hotline will help
ware-controlled. ESI[tronic] 2.0 from Bosch provides the
you deal with any problems in repair and repair work.
service center with the necessary target and actual value
Advice is on hand from experts with years of experience
data.
in automotive engineering, backed by all the original
ESI[tronic]-K: Component ESI[tronic]-K: Component repair instructions
equipment know-how and comprehensive strength that
ESI[tronic]-D: Diesel replacement parts
only Bosch can offer.
ESI[tronic]-W: Test values for in-line and distributor
Bosch diagnostics: the full package
injection pumps and software for injector repair
Bosch offers diesel service centers a full range of equipment and comprehensive backup in all workshop
TestData CD
matters:
Test and setting values for VP29/30/44 and test values
Testing systems
for CR pumps, CR injectors, UI and UP products.
ESI[tronic] 2.0 software
Special tools
Know - how built on diesel training is the basis
Service training
A key prerequisite for the correct use of injector repair
Technical hotline
tools is an induction course at a Bosch Training Center. It is particularly important to take the course when preparing to handle complex servicing procedures such as CRI / CRIN.
ESI[tronic] 2.0: Modular workshop software
Training: for field repair procedures
Technical hotline and knowledge database 11
What drives you, drives us. Technology from Bosch is used in practically every vehicle in the world. For us, the focus is on people and helping them to stay mobile. We have been dedicated to people for more than 125 years with our pioneering spirit, research, production and expertise. Our dedication is an unwaivering commitment to providing them with a unique combination of parts, diagnostics, workshop equipment and services:
Bosch products and services
state-of-the-art solutions for efficient vehicle repairs innovative workshop equipment and software – also available on favorable lease terms
the world’s largest range of new and remanufactured spare parts
fast, reliable delivery service
expert customer care via our hotline
extensive range of training courses
specific sales and marketing support
plus many other services
Robert Bosch GmbH Automotive Aftermarket Business Unit Automotive Service Solutions 73201 Plochingen Germany www.bosch-workshopworld.de
. s e g n a h c m a r g o r p d n a l a c i n h c e t o t t c e j b u S
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Fair repair: repairs in line with the market value
Fast and reliable: most work completed within 48 hours
Quality remains priority: Bosch is committed to this as a globally leading original equiment manufacturer
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