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
Trend on the diesel market
Rapid developments in diesel technology
Technical innovations are bringing change to the world
of diesel at an ever accelerating pace. The main drivers
of this trend are new legal requirements, more stringent
emissions standards and also new system functionality,
such as pre-injection.
Bosch boosting diesel popularity
State-of-the-art diesel systems from Bosch, featuring
Common Rail high-pressure pumps and injectors, have
not only set the standard for modern-day diesel vehicle
performance. They have also made diesel more popular
thanks to the fuel economy and smoother drive they
offer. Bosch has to date fitted more than 50 million
diesel injection systems as original equipment world-
wide. And that means an incredible total of over
350 million injectors.
Diesel success as a service opportunity
There are large numbers of diesel-powered vehicles on
the roads, and so more and more vehicles with high-
pressure injection systems are being brought into
service centers for diagnostics, testing and repair.
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2007 2010 2013 2016
In order to provide diesel customers with professional,
cost-effective repair solutions, it is becoming ever more
vital for vehicle service centers to have expertise in the
latest fuel injection systems.
CRI (Common Rail injectors for passenger cars) and
CRIN (Common Rail injectors for commercial vehicles)
on the diesel service market
Testing and replacement of injectors is becoming an ever
more vital part of diesel service. Emissions are subject
to increasingly tight controls. Engine performance and
fuel efficiency have to be balanced. Consequently, CRI /
CRIN servicing is becoming a benchmark for customer
satisfaction.
Benefits from the complete injector servicing package:
What began in 2005 as merely a nozzle replacement
service has since grown into a complete backup package.
Immediately you can:
Interchange all injector components

Service all current Bosch solenoid-controlled


injectors till – up to 1800 bar (CRI 1.0-2.2; CRIN 1-3)
to factory standard
Take on practically any repair job


Tools for complete repair
of Common Rail injectors

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Repair tools
for Common Rail injectors
Assembly and measurement fixture
The right tools for efficient repair
To ensure professional repair of Common Rail injectors
for cars and commercial vehicles (CRI / CRIN) by service
centers, Bosch provides a set of precision tools specially
tailored to the demands of modern-day diesel products.
Digital dial gage CRR 420
Bosch service equipment is subject to the same
standards as are applied in injector manufacture.
As one illustration, the digital dial gage measures
to an accuracy of 1 / 1000 mm.
Digital dial gage with pneumatic damper Measurement adapters and calibration tools
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Complete tool set
Assembly and measurement fixture
The data recordings by the digital dial gage and measure­ment
adapters are reliably and accurately saved to the service program.
Digital angle / torque wrench CRR 320
The unit's integrated database enables it to handle any
tightening torques and angles, such as on measuring tools,
nozzle retaining nuts and valve clamping screws.
Measurement adapters and calibration tools
The package of measurement heads, adapters, calibration
fittings and component fixtures enables all injector
components to be precisely calibrated.
Digital angle / torque wrench

Armature stroke control unit CRR 220 /
Pneumatic control unit CRR 120
A pneumatic control unit and defined application of
measurement forces ensure reproducibility of measured
values and conformance to tolerances within the µm range.
The repair software CRR 920
For efficient calibration of functional parameters,
data recording and calculation of shim thicknesses
for the respective processing step.
Armature stroke and pneumatic control units Repair software
Pneumatic fitting tool
Pneumatic fitting tool CRR 130
Depending on the injector type, solenoid assemblies
may be fitted with a stop sleeve. To remove and refit it,
a defined force needs to be applied, with a short press
time, activated by the pneumatic control unit CRR 120.
CRI / CRIN shims
A wide range of options (shim graduations from
2 to 10 µm) are available for injector adjustment.
The color coding simplifies finding the appropriate
washer(s).
CRI / CRIN shims
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The systematic approach to repair:
Sequence outlined briefly
Dial gage, measurement adapter and angle / torque wrench
Optimal repair sequence
The various individual steps must follow one another
exactly for the repair:
ff Measurement "Armature stroke, electric"
For a time-saving receiving inspection
ff Measured value NOK, injector faulty
Start of repair: Clean thoroughly in ultrasonic bath,
disassemble injector
ff Measured value OK
Hydraulic test on test stand
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Armature stroke / pneumatics control unit measurement
ff Visual inspection (based on fault illustration diagrams
from the service manual). If defective parts are
identified, they are replaced.
ff Calibration of functional parameters and step-by-
step assembly of the injector.
ff Interim check: Electrical armature stroke measure-
ment, revealing possible assembly errors (e.g. valve
ball forgotten).
ff Measured value OK, repair completed
Test on the EPS 815 / EPS 708, determine code as
necessary.
Servicing systems
delivering genuine benefit

The software indicates which shim is needed Shim fitting

Repair software with user guidance CRR 920
ff Simple sequencing of complex repair procedures
ff Software calculates required shim thickness for
precision calibration without rework
Tightening torques and angles directly from a database
No need for time-consuming manual adjustment of
torque and rotation angle disk.
Upgraded fitting tool
No need for time - consuming switching to different
fixture during assembly.
Groundbreaking full repair package
ff Replacement of injector body, all component
assemblies and single parts
ff Repair options for defects which were until now not
repairable
ff Efficient servicing based on coordinated tooling and
user guidance
ff Optimum injector setting based on use of specially
graduated shims

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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
new to you, and you have already invested in the first
stages of the CRI /CRIN repair package. You can continue
to use the stage 1 fixture for removal. The stage 2 fixture
will serve in future as a fitting and measuring tool. This
approach is a practical aid in attaining the essential
degree of cleanliness. The dismantling and assembly
processes are strictly separated.
Stage 1 of the CRI and CRIN repair package comprises
the tool set for replacement of the diesel injector nozzles.
Stage 2: Replacement of the high-pressure sealing ring
The stage 2 procedure can also be applied to replace the
high-pressure ring on the Common Rail injector.

Stage 1: Nozzle replacement Stage 2: Replacement of the high-pressure sealing ring

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Cleanliness is essential
to diesel repair
A work bench for professionals
Cleanliness, cleanliness, cleanliness!
Cleanliness is vital when working on diesel equipment.
The electrical and mechanical components of modern-
day diesel systems are subject to the highest quality
demands. That is true especially of high-pressure pumps
and injectors in Common Rail systems. Even the tiniest
contaminants can cause them to malfunction.
Divided room concept
Spatial separation of the preliminary cleaning step out-
side the "closed room" from the disassembly, cleaning
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
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4
3
6
7
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
Practical layout of a service area
Ultrasound bath: thorough cleaning
High-efficiency pressure jets from state-of-the-art ultra­
sonic systems ensure that all parts, including the fine
nozzle holes of the injectors, are cleaned without damage.
A work bench that assures top quality
The diesel work bench is the essential basis for
profes­sional, error-free repair of all diesel
components, from conventional systems to state-of-
the-art diesel injection technology. It may be fitted out
with different tool boards depending on the repair case.
State-of-the-art diesel work bench
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Bosch testing systems
for Common Rail injectors

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”)
for solenoid-controlled injectors now expands the
possibilities of diesel servicing even further. After
servicing, the injection quantities of the injectors are
tested in the tried and proven way.
Common Rail injectors are high-tech components which will
work properly only if they are kept within the tightest tole-
rances. That is demonstrated by the check using the EPS 815
and the corresponding supplementary equipment sets.

Test kit for EPS 815 for the testing of Common Rail overview of components

Supplementary set CRIN for

CRI 846 H for cars comm. veh.

Supplementary set CRI Delphi /

CRI / CRIN 848 H Denso

EPS 815 CRS 845 CRI

Diesel Common Rail Accessory set CP1 Piezo
injection pump pump
test rig supplementary CRI 2.5
Accessory set CP2 (CRI 2-18, 2-20)
equipment set
Adapter set for new
injector generation
Accessory set CP3

Accessory set CP4

Accessory set CB18

Accessory set CB28

Accessory set CP
Delphi/Denso/Siemens

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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
The entire diesel testing and repair procedure is soft-
ware-controlled. ESI[tronic] 2.0 from Bosch provides the
service center with the necessary target and actual value
data.
ff ESI[tronic]-K: Component repair instructions
ff ESI[tronic]-D: Diesel replacement parts
ff ESI[tronic]-W: Test values for in-line and distributor
injection pumps and software for injector repair
TestData CD
Test and setting values ​​for VP29/30/44 and test values ​​
for CR pumps, CR injectors, UI and UP products.
Know - how built on diesel training is the basis
A key prerequisite for the correct use of injector repair
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 provided by the diesel specialists
Saving you both time and money, the Hotline will help
you deal with any problems in repair and repair work.
Advice is on hand from experts with years of experience
in automotive engineering, backed by all the original
equipment know-how and comprehensive strength that
only Bosch can offer.
Bosch diagnostics: the full package
Bosch offers diesel service centers a full range of
equipment and comprehensive backup in all workshop
matters:
ff Testing systems
ff ESI[tronic] 2.0 software
ff Special tools
ff Service training
ff Technical hotline
Technical hotline and knowledge database
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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:

 state-of-the-art solutions for efficient vehicle repairs Bosch products and services
 Diagnostics
 innovative workshop equipment and software – also available on  Diesel systems
favorable lease terms  Gasoline systems
 Brake systems
 the world’s largest range of new and remanufactured spare parts  Spark plugs
 Energy systems
 fast, reliable delivery service
 Batteries
 expert customer care via our hotline  Filters
 Wiper systems
 extensive range of training courses  Light technology
 Comfort electronics
 specific sales and marketing support  Hybrid/e-mobility
 Technical hotline
 plus many other services Subject to technical and program changes.  Knowledge database
 Service training
 Workshop concepts

Robert Bosch GmbH

Automotive Aftermarket Bosch electronic repair service
AA-AS/MKC F 026 P02 825 / 201408

Business Unit Automotive Service Solutions  Fair repair: repairs in line with the market
value
73201 Plochingen  Fast and reliable: most work completed
Germany within 48 hours
www.bosch-workshopworld.de  Quality remains priority: Bosch is committed
to this as a globally leading original equiment
manufacturer
Find out more at:
https://www.bosch-repair-service.com/