MAKTEST, INC. 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 Which part has what affect on the deliveries? ............................................................................................. 33 Ball Lift ....................................................................................................................................................... 33 Distance between the Solenoid and the Magnet Plate ............................................................................. 33 Thickness of the Solenoid Shim ................................................................................................................. 33 Nozzle Lift .................................................................................................................................................. 33 Thickness of the Nozzle Spring Shim ......................................................................................................... 34 Bosch CRI Repair Instructions 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 1 Bosch CRI Repair Instructions Spacer is placed in a guide (2) and spacer is much smaller that piston type spacer. Differences in Valve Mechanism Assemblies CRIN 1 Type Valve Mechanism 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). 2 Bosch CRI Repair Instructions Disassembling Nozzle and Checking for Repair Use Maktest Injector Clamp (KO1495) to remove the Nozzle Holder. Remove the Nozzle, Be careful not to drop any small components. 3 Bosch CRI Repair Instructions Piston Type Spacer Remove the injector from the injector clamp, and make sure not to drop any pieces. Put all the components: 1. 2. 3. 4. 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. Spacer in a Guide Type Remove the injector from the injector clamp, and make sure not to drop any pieces. Put all the components: 1. 2. 3. 4. 5. 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. Dissembling the Solenoid and the Valve Group The adjustment shims in the Solenoid section of the injector is often confused with the shim on the nozzle side. Please pay attention to put the components of the nozzle side 4 Bosch CRI Repair Instructions and the components of the solenoid side to different locations in the tray not to mix them. 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. 5 Bosch CRI Repair Instructions 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. Use a torque wrench to remove the control valve nut. The loosening torque must be lower than 120 Nm. Any higher force needed to release the nut is a sign of mistreatment before arriving to repair. 6 Bosch CRI Repair Instructions Remove the nut (1) and note that the support of the nut is facing the control valve. Remove the ball (2) and its housing (1). 7 Bosch CRI Repair Instructions 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. 8 Bosch CRI Repair Instructions Assembling CRI Injectors Assembling the Valve Seal 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. 9 Bosch CRI Repair Instructions Push the arm (1) inside the injector. Fix the arm position by tightening the lock screw (3). Turn the arm knob (1) until it touches the hub and cannot turn more. 10 Bosch CRI Repair Instructions 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. 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 Bosch CRI Repair Instructions Assembling the Control Valve 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 Bosch CRI Repair Instructions Assemble the fixing nut (1) as shown in the figure. Make sure that the correct side of the fixing nut is facing the control valve. Use below values for tightening straight hexagonal fixing nuts. Initial tightening: 50 Nm. Release angle must be larger than 45°. If it releases earlier, change the fixing nut. Fixing: 5 Nm (hand tight). Final tightening: 65 Nm (must be reached between 18 to 22°) Use below values for tightening star fixing nuts. Initial tightening: 70 Nm. Release angle must be larger than 45°. If it releases earlier, change the fixing nut. Fixing: 23 Nm (hand tight). Final tightening: 75 Nm (must be reached between 11 to 15°) 13 Bosch CRI Repair Instructions Assembling Valve Group of CRIN 1 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 Bosch CRI Repair Instructions Mount the Dial Gauge with the long extension. Reset the Dial Gauge to zero. Press the Dial Gauge to read the maximum allowed movement of the magnet plate. 16 Bosch CRI Repair Instructions Compare the value read with the original. Change the adjustment shim (2) shown below to set the lift to correct setting. 17 Bosch CRI Repair Instructions 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 Bosch CRI Repair Instructions 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. Changethe shim (1) to set it between 0.04 and 0.06 mm. 20 Bosch CRI Repair Instructions Assembling the Solenoid Group Place the shim (2) on the push pin (1). Place the Solenoid Spring (1) on top of the shim (2). 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 Bosch CRI Repair Instructions Tightening Torques and Procedures Apply below procedures for tightening the solenoid with complete fixing nut: Initial tightening: 25 Nm. Release angle must be larger than 45°. If it releases earlier, change the solenoid nut. Fixing: 7 Nm (hand tight). Final tightening: 36 Nm (must be reached between 14 to 18°) Apply below procedures for tightening the solenoid with 28 mm Nut: Initial tightening: 25 Nm. Release angle must be larger than 45°. If it releases earlier, change the solenoid nut. Fixing: 7 Nm (hand tight). Final tightening: 36 Nm (must be reached between 10 to 14°) Apply below procedures for tightening the solenoid with 27 mm Nut: Initial tightening: 25 Nm. Release angle must be larger than 45°. If it releases earlier, change the solenoid nut. Fixing: 7 Nm (hand tight). Final tightening: 34 Nm (must be reached between 14 to 18°) Apply below procedures for tightening the solenoid with 30 mm Nut: Initial tightening: 25 Nm. Release angle must be larger than 45°. If it releases earlier, change the solenoid nut. Fixing: 7 Nm (hand tight). Final tightening: 36 Nm (must be reached between 28 to 32°) 22 Bosch CRI Repair Instructions Assembling the Nozzle Assemble the parts as per the type of the injector following the procedures described below: Piston Type Spacer 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. Assemble the Dial Gauge and reset it to zero. 23 Bosch CRI Repair Instructions 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. Change the piston type spacer if needed. Place the pins and assemble the nozzle and the nozzle holder on the pins. Use clamp to fix the nozzle on the pins. 24 Bosch CRI Repair Instructions Tighten the nozzle as per the procedure described below: Tightening Torque Values for 0 445 120 008 Initial tightening: 55Nm. Release 45°. Fixing: 5 Nm (hand tight). Final tightening: 70 Nm to be reached between 38 to 42° Tightening Torque Values for Injectors except 0 445 120 008 Initial tightening: 60 Nm. Release 45°. Fixing: 5 Nm (hand tight). Final tightening: 90 Nm to be reached between 43 and 47° 25 Bosch CRI Repair Instructions Guided Shim Type Spacer 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 Bosch CRI Repair Instructions Place the pins on the injector body. Locate the tool on the pins and make sure that thin extension is placed into the guide and sitting on the shim. 28 Bosch CRI Repair Instructions 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. Use clamp to fix the nozzle on the pins. 29 Bosch CRI Repair Instructions Tighten the nozzle as per the procedure described below: Tightening Torque Values for 0 445 120 008 Initial tightening: 55Nm. Release 45°. Fixing: 5 Nm (hand tight). Final tightening: 70 Nm to be reached between 38 to 42° Tightening Torque Values for Injectors except 0 445 120 008 Initial tightening: 60 Nm. Release 45°. Fixing: 5 Nm (hand tight). Final tightening: 90 Nm to be reached between 43 and 47 30 Bosch CRI Repair Instructions Testing the Injectors and Interpreting the Results Below test should be done after assembling the injector as per instructions above, and making sure that the dimensions in assembly has been adjusted according to the specifications of the injector. Standard test consist of 6 steps: 1. Warm-up, injector is run at this stage for a certain amount of time, depending on the delivery of the injector. Higher the delivery makes the injector warm up time shorter. 2. Leak test, injector is exposed to high pressure without the sending any signals to run the injector. This is for testing the leakage from a. Seal, b. Control valve and piston surface c. Control valve ball seat surface. d. General assembly of the injector Return test oil amount is measured and compared with the target values. If the result is higher than specified target limits, the test should be stopped and there is no need to test the remaining steps. 3. High Pressure Delivery Test is for determining the condition of the nozzle. The amount being delivered may be less. This means that the nozzle holes have been narrowed due to wear out. The delivery may be higher, presenting a sign of wear out in ball seat, causing extensive injection time. This should also be compared with the return value, as this case will increase the return test oil amount too. The delivery may be acceptable but if the return is higher, there is a high possibility of high test oil return from the nozzle (provided that the leak test was acceptable). 4. Low Pressure Delivery Test is for determining the nozzle condition at low pressure. The amount is expected to be lower than if the nozzle holes are narrowed. If the delivery is higher than the limits, the nozzle seat is worn out and leaking even after the injection is ended. 5. Spray test with high pressure is for determining the spray pattern and angles. 6. Spray test at low pressure is for determining the leaking at low pressure, in case the nozzle needle is not sealing off the test oil after the injection is ended. Visual check is necessary to determine this factor and stop the knocking sound at idling. 31 Bosch CRI Repair Instructions Fine Tuning the Delivery of Common Rail Injector If the injector is slightly off the limits, it can be adjusted to fit into the limits. This is often needed when using different brand spare parts and nozzles. Which part has what affect on the deliveries? Ball Lift Ball lift must be adjusted when assembling the injector. Mechanical dimension check is usually enough to make sure that the ball lift is regulating the pre-injection correctly. Change the thickness of the shim (1) shown in the figure to adjust the ball lift. As the setting of ball lift is possible with measurement only, the pre injection test is not necessary on the test bench. However a pre-injection delivery test can be generated. Please refer to section “creating your own test plans”. Higher the Ball Lift setting is higher the pre injection delivery. Distance between the Solenoid and the Magnet Plate Distance between the solenoid and the magnet plate is the first setting for all delivery levels at all pressures. The induction power on the magnet plate affects the response behavior of the injector to the signal. If this distance is too close it damages the solenoid, if this distance is too far, the delivery levels are low and target levels cannot be met. This distance should be adjusted to 0,04 – 0,06 mm to able to have a most effective performance. This distance also changes the current that the solenoid withdraws from the ECU. Therefore if this distance is set too far, the current to pull the magnet plate will be higher and will cause the ECU to generate fault after a while. Adjust the distance with changing the thickness of the washer (2) shown in the figure to adjust the distance. Higher the distance is lower the delivery at especially middle pressure levels. Thickness of the Solenoid Shim Solenoid shim thickness changes the load for the solenoid to overcome at the start of the injection. The thinner shim causes the injector to open fast and close slow, increasing the deliveries at all pressure levels. Thicker shim is causing the solenoid to act late but close fast, and reduces the delivery at all pressure levels. Like all other settings, thickness of this shim can be changed within some certain limits, and outside of these limits causes the injector behave unpredictable. Adjust the load on the spring using the special simulator designed for testing the load on the solenoid, only after setting the distance and the ball lift correctly. Change the thickness of the shim (3) shown in the figure to adjust the load to the correct setting. Thicker the solenoid shim is lower the delivery at all pressure levels. Nozzle Lift Nozzle lift is controlled by either the piston spacer thickness or the spacer shim in the guide. If we increase the nozzle lift, we increase the delivery at high pressure levels only. Changing this shim has no affect on other pressure levels. 33 Bosch CRI Repair Instructions Thicker the spacer shim lower the delivery a high pressure levels. Thickness of the Nozzle Spring Shim Nozzle Spring has an important affect on idle delivery. The thicker the shim lowers the idle delivery. However the thicker shim increases the start of injection pressure. 200 bar spray test are crucial to determine if the thickness of this shim caused to stop spaying at low pressures. Amount of injection is not important but, injection should be visible at 200 bars spray test. Do not try to repair a leaking injector with increasing the thickness of the nozzle spring shim. This will certainly cause the injector to change delivery behavior at different pressure levels. Thinner the Nozzle Spring Shim is Higher the Idle Delivery 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
