Académique Documents
Professionnel Documents
Culture Documents
Service Manual
Bosch CRIN Types 1, 2, 3
01.09.2009
Disclaimer: The information presented herein is for guidance only. Different applications may have different
service procedures to follow. Consult to Maktest in case of confusion.
Contents
Description of Components ................................................................................................................................. 1
Identification of CRIN types and their Differences .......................................................................................... 1
CRIN 1 Type; Piston Type Spacer ................................................................................................................. 1
Piston Spacer in a Guide .......................................................................................................................... 1
Differences in Valve Mechanism Assemblies .............................................................................................. 2
CRIN 1 Type Valve Mechanism ................................................................................................................ 2
CRI 2.0 and CRI 2.2 type Valve Mechanism ............................................................................................. 2
Disassembling Nozzle and Checking for Repair ................................................................................................... 3
Piston Type Spacer ...................................................................................................................................... 4
Spacer in a Guide Type ................................................................................................................................ 4
Dissembling the Solenoid and the Valve Group .................................................................................................. 4
CRIN 1 Type ..................................................................................................................................................... 5
Assembling CRI Injectors ..................................................................................................................................... 9
Assembling the Valve Seal ............................................................................................................................... 9
Assembling the Control Valve ....................................................................................................................... 12
Assembling Valve Group of CRIN 1 ................................................................................................................ 15
Measuring and Setting the Magnet Plate Lift............................................................................................ 15
Measuring and Setting the Distance between Solenoid and Magnet Plate.............................................. 19
Assembling the Solenoid Group .................................................................................................................... 21
Tightening Torques and Procedures.......................................................................................................... 22
Assembling the Nozzle................................................................................................................................... 23
Piston Type Spacer .................................................................................................................................... 23
Measuring and Setting the Nozzle Lift of Injectors with Piston Type Spacers ...................................... 23
Tightening Torque Values for 0 445 120 008 ........................................................................................ 25
Tightening Torque Values for Injectors except 0 445 120 008.............................................................. 25
Guided Shim Type Spacer .......................................................................................................................... 27
Measuring and Setting the Nozzle Lift................................................................................................... 27
Tightening Torque Values for 0 445 120 008 ........................................................................................ 30
Tightening Torque Values for Injectors except 0 445 120 008.............................................................. 30
Testing the Injectors and Interpreting the Results ............................................................................................ 31
Fine Tuning the Delivery of Common Rail Injector............................................................................................ 33
Description of Components
Identification of CRIN types and their Differences
CRIN 1 Type; Piston Type Spacer
Piston Type Spacer (2) is actually located between nozzle needle and Control Valve Piston.
Piston Spacer in a Guide
CRIN 1 type of Valve Mechanism (1) sits freely on the control valve fixing nut, as a complete assembled unit.
As long as the ball lift is measured correctly and adjustable with the shim, there is no need to disassemble
this complete assembled valve mechanism.
There are 2 shims of same hexagonal shape, one of which is placed under the valve mechanism (2). This shim
is used to adjust the ball lift. The other shim sitting on the top of the valve machanism is for setting the
distance between the solenoid and the valve magnet plate.
CRI 2.0 and CRI 2.2 type Valve Mechanism
CRIN 2 and CRIN 3 types have the same Vale mechanism with magnet plate and freely placed push pin (2).
Pins
Piston type spacer
Spring
Shim
in a clean pan together with the injector. Make sure that all components from the same injector is put into
the same pan. Do not mix the parts from different injectors.
Pins
Spacer
Guide
Spring
Shim
in a clean pan together with the injector. Make sure that all components from the same injector is put into
the same pan. Do not mix the parts from different injectors.
CRIN 1 Type
Remove the solenoid completely, pay attention not to drop the adjust shim (2) and the spring (1).
Spring (1) and the shim (2) be stuck in the solenoid hole.
Make sure these items are not mixed with nozzle spring and shim.
Use tweezers to remove the sealing o-ring off the solenoid group.
Remove the valve mechanism completely. Do not attempt to disassemble the valve mechanism.
Make sure not to mix shims (1) and (2) which have different thicknesses.
Remove the nut (1) and note that the support of the nut is facing the control valve.
Use Maktest Valve (KO1376) puller to remove the valve easily. Make sure to set the puller on top position
before placing the puller inside the injector body to grip the valve.
Turn the nut clockwise to clamp on the control valve. Pull firmly VERTICAL to remove the control valve out of
the injector body.
Do not try to pull by turning or sideways, as the injector body may be damaged to
cause leaking.
Be careful that the pin may come out together with the control valve.
Remove the high pressure seal (1) and its support ring (2) from the injector body.
Use the KO1509 High Pressure Seal Assembly Tool to mount the high pressure seal into the injector.
(1) Push arm
(2) Lock
(3) Hub
Release the both locks and turn the pull arm back as much as possible. Unscrew the knob on the push
arm as much as possible.
Place the dummy seal (1) on the push arm end (2)
Mount the hub on the injector, keeping the arm out of the injector. Screw the hub as much as possible
and even tighten it with your hand without using any tools.
10
The seal (2) and the support ring (1) should look like as shown on the above picture. Make sure to place
the support ring the cavity on the ring should face the seal to be able to support the seal.
Screw the hub in the injector body as much as possible and tighten it with your hand. Do not use any
tools to tighten it.
Push the arm into the injector body and feel the seal is placed in the injector body. Pull the arm back and
unscrew the hub. The seal is placed to its housing inside the injector body.
11
Place the valve (1) and the pin (2) in to the injector (3) as shown on the above picture.
Use KO1510 control valve assembly tool to push the valve into the seal until it rests on its seat.
Screw the hub (2) as much as possible. Turn the push arm (1) slowly to allow the control valve to
slide into the seal.
12
13
Drop the ball (1) to its seat then place the ball holder on top of the ball.
Place freely the complete valve assembly. Pay attention to the shim (2) and (1) has the correct thickness.
Measuring and Setting the Magnet Plate Lift
Before assembling the solenoid group, make sure that the magnet plate lift is set to the original value to
obtain the right delivery amount.
Assemble the KO1381 Valve Lift Measurement Tool on the injector body as shown in the picture.
15
Press the Dial Gauge to read the maximum allowed movement of the magnet plate.
16
17
Measuring and Setting the Distance between Solenoid and Magnet Plate
The distance should be set to 0.04 to 0.06 mm.
Measure the Solenoid depth using KOXXXX. Use the tool as shown in the figure. Make sure to zero the dial
gauge on an even surface to obtain maximum accuracy.
19
Measure the Magnet Plate depth using the KOYYYY. Use the tool as shown in the picture. Make sure to zero
the dial gauge on an even surface to obtain maximum accuracy.
Deduct the height of the Magnet Plate from the Solenoid Depth to calculate the distance between solenoid
and the magnet plate.
20
Put some lubricant to the threads of solenoid nut (1) and injector body (2).
Place the solenoid vertically on the injector body and apply vertical force downwards while turning the
solenoid slightly right and left. Do not try to turn the solenoid complete 360 degrees.
Pay attention to the position of high pressure inlet with respect to the cable connection to avoid any
mounting problems to the engine, if the Solenoid has connector type cable connection.
21
22
Place the injector spring adjustment shim (4) into the injector body.
Put the injector spring (3).
Place the piston type spacer (2).
Measuring and Setting the Nozzle Lift of Injectors with Piston Type Spacers
Assemble the KO1378 nozzle lift adjustment tool on the injector body. Make sure
that the main hub is screwed completely down onto the flat end of the injector body.
23
Screw the push pin down by turning the knob on the tool until it is blocked. Read the
lift. Compare it with the original value.
24
25
Place the injector spring adjustment shim (5) into the injector body.
Put the injector spring (4).
Place the Guide for the Shim (3).
Place the shim inside the guide (2).
Measuring and Setting the Nozzle Lift
Mount Dial Gauge on the KO1379 nozzle lift measurement tool. Use thin end
extension, see picture.
Reset the Dial Gauge to zero on the flat surface of the KO1495 Injector Clamp.
27
Locate the tool on the pins and make sure that thin extension is placed into the
guide and sitting on the shim.
28
Measure the value as a drop below the zero level and compare it with the original
value.
Change the shim if needed.
Assemble the nozzle and the nozzle holder on the pins.
29
30
31
Results on Delivery
Parameter
Ball Lift
Distance between
Solenoid and
Magnet Plate
Solenoid Shim
Nozzle Lift
Nozzle Spring
Shim
34
Return
High Pressure
Middle Pressure
Pre-Injection
Idle
increase
+++
NO
decrease
---
NO
increase
---
NO
decrease
+++
NO
increase
--
--
--
--
decrease
++
++
++
++
increase
+++
NO
NO
NO
NO
decrease
---
NO
NO
NO
NO
increase
---
NO
decrease
+++
NO