Common Rail injectors

Testing, dismantling, and now

-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 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 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 service. 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 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 servicing 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 vehicles on

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

Take on practically any repair job


Tools for complete repair

of Common Rail injectors

Repair tools
for Common Rail injectors

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 measurement

for cars and commercial vehicles (CRI/CRIN) by service

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.

standards as are applied in injector manufacture.

As one illustration, 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,

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

ff Visual 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.

ff Measurement "Armature stroke, electric"

For a time-saving receiving inspection
ff Measured value NOK, injector faulty

ff Calibration of functional parameters and step-bystep assembly of the injector.

ff Interim check: Electrical armature stroke measure-

Start of repair: Clean thoroughly in ultrasonic bath,

ment, revealing possible assembly errors (e.g. valve

disassemble injector

ball forgotten).

ff Measured value OK
Hydraulic test on test stand

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

Groundbreaking full repair package

ff Simple sequencing of complex repair procedures

ff Replacement of injector body, all component

ff Software calculates required shim thickness for

precision calibration without rework

assemblies and single parts

ff 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.

ff Efficient servicing based on coordinated tooling and

user guidance
ff Optimum injector setting based on use of specially
graduated shims

Upgraded fitting tool

No need for time-consuming switching to different
fixture during assembly.

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

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 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
2

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 service 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 ultra

The electrical and mechanical components of modern-

sonic systems ensure that all parts, 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

contaminants can cause them to malfunction.

The diesel work bench is the essential basis for

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. It may be fitted out

side the "closed room" from the 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 diesel work bench

9

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)

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 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

Accessory set CP3
Accessory set CP4
Accessory set CB18
Accessory set CB28
Accessory set CP
Delphi/Denso/Siemens

10

CRI 2.5
(CRI 2-18, 2-20)
Adapter set for new
injector generation

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

ff ESI[tronic]-K: Component repair instructions

equipment know-how and comprehensive strength that

ff ESI[tronic]-D: Diesel replacement parts

only Bosch can offer.

ff 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

ff Testing systems

for CR pumps, CR injectors, UI and UP products.

ff ESI[tronic] 2.0 software

ff Special tools

Know-how built on diesel training is the basis

ff Service training

A key prerequisite for the correct use of injector repair

ff 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:
state-of-the-art solutions for efficient vehicle repairs

Bosch products and services

innovative workshop equipment and software also available on

favorable lease terms

Diesel systems

Diagnostics
Gasoline systems
Brake systems

the worlds largest range of new and remanufactured spare parts

Spark plugs
Energy systems

fast, reliable delivery service

Batteries

expert customer care via our hotline

Filters

extensive range of training courses

Light technology

Wiper systems
Comfort electronics

specific sales and marketing support

Robert Bosch GmbH

Automotive Aftermarket
Business Unit Automotive Service Solutions
73201 Plochingen
Germany
www.bosch-workshopworld.de

Subject to technical and program changes.

Technical hotline

AA-AS/MKC F 026 P02 825 / 201408

plus many other services

Hybrid/e-mobility
Knowledge database
Service training
Workshop concepts

Bosch electronic repair service

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
Find out more at:
https://www.bosch-repair-service.com/