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Service Manual
Bosch CRI Types 1.0, 2.1, 2.2
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
Explanation of Name Plate on the Injector ..................................................................................................... 1
Identification of CRI types and their Differences ............................................................................................ 2
Differences in Nozzle Seat ........................................................................................................................... 2
Piston Type Spacer .................................................................................................................................. 2
Piston Spacer in a Guide .......................................................................................................................... 2
Differences in Nozzle End Surface ............................................................................................................... 3
Solid Nozzle End-Machined Surface ........................................................................................................ 3
Nozzle Seat with Maltese Cross Machined Surface................................................................................. 3
Nozzle Seat with Butterfly Shape Machined Surface .............................................................................. 3
Differences in Valve Mechanism Assemblies .............................................................................................. 4
CRI 1 type Valve Mechanism ................................................................................................................... 4
CRI 2.0 and CRI 2.2 type Valve Mechanism ............................................................................................. 5
CRI 2.1 type Valve Mechanism ................................................................................................................ 5
Disassembling Nozzle and Checking for Repair ................................................................................................... 7
Piston Type Spacer ...................................................................................................................................... 8
Spacer in a Guide Type ................................................................................................................................ 8
Checking For Repair ......................................................................................................................................... 9
Dissembling the Solenoid and the Valve Group ................................................................................................ 10
Dissembling the Solenoid and the Valve Group CRI 2.1 Type (BMW applications) .......................................... 14
Dissembling the High Pressure Inlet Nipple .................................................................................................. 16
Checking Components for Repair .................................................................................................................. 16
Assembling CRI Injectors ................................................................................................................................... 21
Assembling the Valve Seal ............................................................................................................................. 21
Assembling the Control Valve ....................................................................................................................... 24
Assembling Valve Group of CRI 1.0, 2.0 and 2.2 ........................................................................................... 25
Daimler Chrysler Engine Applications Suspension Ring Assembly .......................................................... 27
Measuring and Setting the Magnet Plate Lift................................................................................................ 27
Measuring and Setting the Distance between Solenoid and Magnet Plate.............................................. 30
Assembling the Solenoid Group .................................................................................................................... 33
Assembling the CRI 2.2 type Solenoid and Valve Group (BMW Applications) .............................................. 34
Assembling the Nozzle................................................................................................................................... 38
Piston Type Spacer .................................................................................................................................... 38
Measuring and Setting the Nozzle Lift of Injectors with Piston Type Spacers ...................................... 38
Tightening Torque Values for Injectors with Flat End ........................................................................... 40
Tightening Torque Values for Injectors with Maltese Cross End .......................................................... 41
Tightening Torque Values for Injectors with Butterfly End ................................................................... 41
Guided Shim Type Spacer .......................................................................................................................... 42
Measuring and Setting the Nozzle Lift................................................................................................... 42
Tightening Torque Values for Injectors with Flat End ........................................................................... 45
Tightening Torque Values for Injectors with Maltese Cross End .......................................................... 46
Tightening Torque Values for Injectors with Butterfly End ................................................................... 46
Testing the Injectors and Interpreting the Results ............................................................................................ 47
Fine Tuning the Delivery of Common Rail Injector............................................................................................ 49
Which part has what affect on the deliveries? ............................................................................................. 49
Ball Lift ....................................................................................................................................................... 49
Distance between the Solenoid and the Magnet Plate ............................................................................. 49
Thickness of the Solenoid Shim ................................................................................................................. 49
Nozzle Lift .................................................................................................................................................. 50
Thickness of the Nozzle Spring Shim ......................................................................................................... 50
Description of Components
Explanation of Name Plate on the Injector
See below figureError! Reference source not found.;
1. Serial Number
2. Bosch Order Code
3. Classification
Piston Type Spacer (2) is actually located between nozzle needle and Control Valve Piston.
Piston Spacer in a Guide
Spacer is placed in a guide (2) and spacer is much smaller that piston type spacer.
This type of nozzle body is used on CRI 1 type Bosch injectors with piston type spacers.
Nozzle Seat with Maltese Cross Machined Surface
Usually guided spacer nozzle assembly injectors have this Maltese cross machined surface on their nozzle
seat surface.
Nozzle Seat with Butterfly Shape Machined Surface
Injectors with both piston type spacers and guided spacers of CRI 2 type may have Butterfly Shape Machined
Surface on their nozzle seat surface.
1
2
3
CRI 1 type of Valve Mechanism is very wide spread and first generation valve mechanism. The lock piece (1)
must be removed in order to disassemble whole valve mechanism. Connection Plate (2) can be removed
only after removing the lock piece, and Control Valve Fixing Nut (3) should be removed using a special
hexagonal tool.
CRI 1 type mechanism has a variant for Daimler Crysler Engines. One type of the Valve Mechanism is
modified to have a suspension (1) on the Control Plate Assembly to avoid uncontrolled vibrations during
operation at higher speeds.
CRI 2.0 and CRI 2.2 is very similar to CRI 1 type valve mechanism, with one exception that there is a
protective cover (1) on top end of the Push Rod. This cover actually covers the lock piece and avoids and
damage to push rod and lock piece. In order to disassemble the valve mechanism, the protective cover (3)
must be removed and then lock piece should be removed to remove the connection plate. After removing
Control Valve Fixing Nut (3), the push rod, ball housing and ball can be removed.
CRI 2.1 type Valve Mechanism
This different design Valve Mechanism does not have any lock piece because the connection plate and push
rod is combined into one single push piece (1) and once the solenoid is removed, it is freely taken out off the
assembly. Likewise the guide housing for push piece (2) is removed freely after push piece is taken out.
Pins
Piston type spacer
Spring
Shim
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
Make sure that all components from the same injector is put into the same pan. Do not mix the parts from
different injectors.
Check the injector body for corrosion. The nozzle holder should be screwed onto corrosion free threads.
The surface should be free of cracks, dents and scratches (1). The injector bodies shown on the right cannot
be repaired.
Remove the spring (2) and the shim (1). Shim may be stuck in the solenoid hole.
Make sure these items are not mixed with nozzle spring and shim.
10
The Washer (1) usually sticks to the solenoid and is removed off the assembly. If not please remove it using a
tweezers from inside the injector body (above left figure).
See below the magnet plate (1) is assembled with a lock piece on the valve mechanism. Magnet plate is the
plate actually pulled by the solenoid to release the metal ball on the control valve. Magnet plate is
supported with a spring.
Push the magnet plate down and remove the lock nut. Hold the magnet plate firmly to control the spring
underneath and lightly release the spring and remove magnet plate and the spring.
11
Remove the nut, and take the rest of the valve mechanism out be careful not to drop the metal ball (4) and
the ball holder (3), that may stick to the push pin (1). The stroke adjustment washer (2) may also stick to the
push pin.
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.
12
Remove the high pressure seal (1) and its support ring (2) from the injector body.
13
Dissembling the Solenoid and the Valve Group CRI 2.1 Type (BMW
applications)
Mark the cable connection position with respect to the high pressure inlet using a
permanent marker to be able to assemble the solenoid in the same position.
Otherwise there may be connection problems when mounting the injector on the
engine.
Remove the solenoid group according to the instructions on Dissembling the Solenoid and the Valve Group
on page 10.
Use tweezers to remove the metal ball holder and its holder.
14
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.
15
Remove the high pressure seal (1) and its support ring (2) from the injector body.
16
High pressure nipple mounting surface should also be damage and corrosion free.
The solenoid body should be damage free and not heavily scratched. Example in picture (1) shows heavily
scratched solenoid valve. Picture 2 shows the light damage that does not have any impact on its
performance.
The connector socket should be damage free. Injector cable must be able to stay connected on the injector
when it is mounted on the engine. Example (1) cannot be assembled on the engine.
17
The Solenoid fixing nut should not be damaged such that prevents to tighten the solenoid on the injector
body. Example (1) cannot be assembled on the injector body.
Solenoid coil should not be damaged. Example (1) shows a damaged solenoid coil.
O-ring channel should be scratch free for complete sealing. Example (1) shows a scratched o-ring channel.
18
Damages on control valve ball seat causes high return and operation failures of common rail injector.
Check the valve seat using a magnifier. The valve seat should be damage and scratch free for a normal
operation. In any doubt change the valve.
Example (4) shows a heavy damage on the valve seat. Example (3) shows also a heavy damage on the valve
seat that causes high return. Example (2) has minor damage that does not affect the performance of the
injector, yet change of the valve is recommended to avoid failures in the near future. Example (1) shows a
new valve seat.
19
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.
21
Fix the knob lock screw (2) too. The hub (4) and the push arm (1) should look like as in the picture above
after setting the position of the seal on the tool.
Unscrew the hub from the injector body. Remove the dummy seal and put the new seal on the tool.
22
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.
23
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.
24
Drop the ball (1) to its seat then place the ball holder on top of the ball.
Place the push pin (1) on top of the adjustment shim and the ball holder.
25
Place the control valve fixing nut (1) in the injector. Make sure that the flat surface is facing the
control valve. Screw the nut in and use KO1377 Valve Fixing Nut Wrench to tighten it. Use torque
wrench for final tightening.
Use below values for tightening fixing nuts in CR injectors type CRI 1, CRI 2.0 and CRI 2.1.
Initial tightening: 38 Nm.
Release angle must be larger than 30. If it releases earlier, change the fixing nut.
Fixing: 5 Nm (hand tight).
Final tightening: 65 Nm (must be reached between 15 to 21)
Use below values for tightening fixing nuts in CR injectors type CRI 2.2
Initial tightening: 50 Nm.
Release angle must be larger than 35. If it releases earlier, change the fixing nut.
Fixing: 5 Nm (hand tight).
Final tightening: 65 Nm (must be reached between 16 to 22)
26
Bosch has developed a suspension ring with an extra spring for Daimler Chrysler. First place the
spring (1) and then freely place the suspension ring on the spring (2).
Place the spring for the magnet plate over the push pin (1).
Place the Magnet Plate over the push pin, on top of the spring. Push the magnet plate with your
hand and place the lock piece to its slot.
27
Mount the Dial Gauge with the long extension and reset it to zero.
28
29
30
Deduct the height of the Magnet Plate from the Solenoid Depth to calculate the distance between solenoid
and the magnet plate.
Change the shim (2) to set it between 0.04 and 0.06 mm.
31
Place the solenoid spring, adjustment shim into the hole on the solenoid body.
Put some lubricant to the threads of solenoid nut and injector body.
33
Assembling the CRI 2.2 type Solenoid and Valve Group (BMW Applications)
Assemble the control valve seal and control valve and pin as per above instructions.
Place the fixing nut (2) and tighten it with your hand as much as possible.
Use below values for tightening fixing nuts in CR injectors type CRI 2.2
Initial tightening: 50 Nm.
Release angle must be larger than 35. If it releases earlier, change the solenoid nut.
Fixing: 5 Nm (hand tight).
Final tightening: 65 Nm (must be reached between 16 to 22)
34
Place the valve pin guide (1) freely on the fixing nut.
35
36
Put some lubricant to the threads of solenoid nut and injector body.
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.
Apply below procedures for tightening the solenoid:
Initial tightening: 25 Nm.
Release angle must be larger than 30. If it releases earlier, change the solenoid nut.
Fixing: 7 Nm (hand tight).
Final tightening: 35 Nm (must be reached between 13 to 17)
37
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.
38
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.
39
40
41
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.
42
Locate the tool on the pins and make sure that thin extension is placed into the
guide and sitting on the shim.
43
44
45
46
47
49
Results on Delivery
Parameter
Ball Lift
Distance between
Solenoid and
Magnet Plate
Solenoid Shim
Nozzle Lift
Nozzle Spring
Shim
50
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