Testing and repair_cri

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Testing and Repair of CRI and CRINTesting and Repair of CRI and CRIN

AA/PDS1 | 03.2005 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

Automotive Aftermarket

Preliminary testing and repair instructionfor solenoid controlled Bosch Common Rail

Injectors of the 1st and 2nd generation

AA/PDS103.2004

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Testing and Repair of CRI and CRIN


Clean Workshop Area


Any repair work on injectorsis to be carried out on work-benches with stainless steelplating according to Boschguidelines.

Other workbench conceptsdo not meet the cleanlinessdemands for repair work on today´s modern Diesel com-ponents!

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General Subjects

Bosch Common Rail injectors may only be repaired:

• After any warranty period of the vehicle or engine has expired

• Outside any in-field compliance periods required by law duringwhich vehicles can be subject to exhaust tests.For an EURO3 vehicle this means three years and < 80.000 km,5 years and 100.000 km for an EURO 4 vehicle.

• Country specific rules and laws are to be obeyed.

Testing of injectors on released test equipment is permitted at any time.

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Special Features

This instruction describes the testing and repair of solenoidcontrolled Common Rail injectors (CRI or CRIN, resp.) of the1st and 2nd generation. Part numbers are 0 445 110 xxx (CRI) and 0 445 120 xxx (CRIN)These injectors are refered to as CRI1 and CRI2 or CRIN1 andCRIN2, respectively.The nozzle change on any CRI or CRIN can only be performed oncein the livecycle of the injector.

CRI1Locating pins are used for aligning the nozzle to the injector body.Some CRI1 are using spiral type locating pins which can not beremoved from the injector body.Injectors with this feature can not be repaired because the locatingpins may break when mounting the nozzle retaining nut.When this happens, the alignment between nozzle and the fuelsupply bore of the injector body is no longer given.

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Testing and Repair of CRI and CRINSpecial features (Continued)

CRI1 Injectors of this generation with cylinder-type locating pinscan be repaired.The locating pins are to be replaced with new ones.

Differences: Types with big pressure pin (top picture) or nozzle guided valve piston (DGV, picture below).The big pressure pin or the DGV-sleeve with a small pressure pin (pill) can not be replaced.These parts, like the nozzle spring and the adjustment shims, can be used again.

CRI2Like CRI1, but no types with big pressure pin, only DGV.Locating pins are always of the cylindrical type.



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Arrows on top picture:CRI with spiral-type locatingpins, nozzle change not possible.

Arrows on bottom picture:CRI with cylinder-type locating pins, nozzle change possible..

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Special features (Continued)

CRI1 and CRI2 The repair depth is limited to a nozzle change.A leak at the high pressure connection can be repaired by replacing both connection and seal..This is not feasible for injectors that feature secured threads (Daimler-Chrysler vehicles).Injectors with this feature must be replaced with exchange- ornew units when a leak occurs at the high pressure connection.

Repair of any other leaks at injector connections or on the injectorbody is not possible.

Repairwork that requires removal of the solenoid retainingnut is also not permitted.

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CRIN Types

CRIN1 or 2, Type 1, Standard Typefor medium duty and heavy duty applications 1 = internal high pressure connection2 = internal return flow connection3 = electrical screw-on connections


1

2

3

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CRIN Types

CRIN1 or 2, Type 2, Standard Typefor light duty and medium duty applications

1 = external high pressure connection2 = external return flow connection3 = electrical plug-on connection

CRIN1 or 2, Type 3, Special Type for light-, medium- and heavy duty applications

1 = external high pressure connection2 = external return flow connection3 = electrical screw-on connections

1

23

12

3



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CRIN Types

CRIN1 or 2, Type 4, Special Type for light-, medium- and heavy duty applications

1 = external high pressure connection2 = internal return-flow connection3 = electrical screw-on connections

1

3



2

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CRIN1The locating pins are to be replaced with new ones.

Differences: Types with big pressure pin (top picture) or nozzle guided valve piston (DGV, picture below).The big pressure pin or the DGV-sleeve with a small pressure pin (pill) can not be replaced.These parts, like the nozzle spring and the adjustmentshims, can be used again.

CRIN2 Like CRI1, but no types with big pressure pin, only DGV.



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CRIN1 und 2 The repair depth is limited to a nozzle change.A leak at the high pressure connection can be repaired by replacing the high pressure fitting.This is not feasible for injectors that feature permanently fixed high pressure fittings.Injectors with this feature must be replaced with exchange- or new units when a leak occurs at the high pressure connection.

Repair of any other leaks at injector connections or on the injector body is not possible.

Repair work that requires removal of the solenoid valveretaining nut is also not permitted.

Bild Permanentfixierung


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Visual Inspection

• Check injector for corrosion and mechanical damage.

• Damaged or incomplete injectors can not be repaired.

• Injectors with strong corrosion or damaged electrical connectionscan not be repaired.

• See pictures on the next pages.

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Lightly soiled/coked injector, repair possible

Medium soiled/cokedinjector, repair stillpossible


Strongly soiled/coked injector, repair notpossible


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Visual Inspection (Continued)Many injector types feature a guiding surface that aligns the injector properlyat its mounting position inside the cylinder head, see picture below, item 1.A separate visual inspection is necessary.After testing and repair, mount the injectors to the same engine cylinderswhere they originally came from.

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Guiding sleeve isin good condition,injector repair possible .

Traces of wear on theguiding sleeve, injectorcan still be repaired.


Guiding sleeve showssignificant wear.Injector repair still possible,check age and mileage ofthe vehicle.

Visual Inspection Of Guiding Sleeve

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Removal of Coarse Dirt

• Plug injector high-pressure and return flow connectionsas well as injector nozzle with plastic caps, check ESI[tronic]spare parts listings.

• Remove coarse dirt and clean injector with cleaningdetergent.Particularly the nozzle must not be cleaned with a wire brush

• Avoid spilling cleaning detergent on the electrical connectors.

• Dry the injector with clean compressed air and remove plastic caps when injector is dry.

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Testing the Injector(s)

• Mount the cleaned injector(s) on the test bench.

• Run the cleaning/bleeding routine.

• Determine the condition of the injector(s) according to the test results.

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Leak Test

Leaks at the high pressure connection:Replace connection and seal with new ones.This is not possible on Daimler-Chrysler vehicles becauseof the secured threads.Some CRIN types feature a permanently fixed high pressureconnection, in this case, repair is not possible .

See chapter „Nozzle Replacement“ for leaks at the nozzle retaining nut.

Injectors with cracked housings, leaking return flow connectionsor leaks at the solenoid valve retaining nut can not be repaired.Replace with Bx-unit or new injector.

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General Information

This chapter describes the testing of Common Rail injectors for both, passenger cars (CRI)and commercial vehicles (CRIN).The Bosch injection test bench EPS 815 with KMA 802 or 822 together with the CRS 845test set is to be used for the testing.The CR basic set 1 687 001 846 is used for testing up to six CRI at the same time.The additional set 1 687 001 599 is used for testing one CRIN at the time.

The use of other test benches or retrofit kits may lead to wrong testing results.

Test specifications for Bosch injectors are published on the TestData CD-ROM.A valid subscription and access code are pre-requisites for using the CD. For additional information, consult ESI[tronic] Hotline.

In general, the test sequences of CRI and CRIN are identical.Depending on the injector generation, e.g. CRI 1 or CRIN2, or differences like codedinjectors, IMA , multi injection (MI), the number of test steps may vary.

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Injectors of Competitors

It is possible to use the EPS 815 test bench with KMA and the necessaryCRI/CRIN test sets for testing injectors from other manufacturers.However, this is within the responsibility of the test bench operator.

The Robert Bosch GmbH does not produce or submit any test dataor specifications for injectors of other manufacturers.

Prior to testing, perform measurements on vehicles with correspondinginjectors in order to determine injector current flow and voltages, thus preventing any damage of the electronics of the test bench.

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Basic Set for CRI Testing (1 687 001 846)

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Additional Set for CRIN Testing (1 687 001 599)

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• Passenger car injectors (CRI) can be tested as a complete set.

• Commercial vehicle injectors can only be tested individually, i.e. oneat the time.

• Use only undamaged high pressure test lines.

• Only the CP 3.3 that comes with the basic test set is to be used as thehigh pressure supply unit.

• When not in use, all hydraulical connections of the pump have to be sealedwith the attached plastic plugs.

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• During the setup of the CRI/CRIN test set the CRS 845rail pressure sensor has to be calibrated!

Test bench pressure value

low high

External pressure value

Prior to new calibration, clear old values first!

DD.MM.YYYY

Actual value in calibration mode!Save with F12 >>

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Injector


seal ring

valve seal pliers


Picture: Removal of the sealring with commerciallyavailable pliers for valve seals, e.g.Hazet 791-5

Remove the seal ring using the pliers for valve seals.To do so, hold the seal ring with the pliers and pull it from the nozzlewith slight turning motions.

After a successful testing of the injector, put a new seal ring on the nozzleshaft and push it into the direction of the nozzle retaining nut.

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Preparing the testing with EPS 815

• Clean the injector around nozzle and nozzle retaining nut.Use a nylon brush for removal of coarse dirt.Wash the cleaned surfaces with cleaning detergent.After that, clean the area of nozzle and nozzle retaining nut in an ultrasoniccleaning bath.Make sure the injector(s) are hanging in a correct angle into the bath andsecure them from falling and tumbling.Add cleaning detergent until the nozzle retaining nut is completely covered.

• Take the injector(s) out of the ultrasonic bath after approx. 15 minutes anddry them with clean compressed air

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Testing• Mount the injector(s) onto the test bench by using the appropriate

electrical and hydraulical adaptors.Consult the test bench manual for further information.

• Shut the doors of the test bench.

• Start the test program, key in the part number and the manufacturingdate of the injector.

• In case of coded injectors or IMA/NIMA, respectively, fill in theinjector code.

• Select test mode, e.g. initial testing or testing after repair andconfirm.

• Automatic testing starts.

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Test Steps

• Leak Test Visual inspection of the entire injector for escaping test oil.Only the high pressure supply and the return flow lines are connected to the injector(s) in order to do perform this test step.Do not connect the injector(s) electrically.

Leaks at the high pressure connection or nozzle retaining nut may be repaired by using new parts.The feasibility depends on the type of injector, see chapter „repair“ ofthis instruction.

All other leaks, e.g. at the solenoid retaining nut can not be repaired.Substitute this injector with a Bx- or new part.

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Injector Testing• Leak Test • Interchange Test

Return flow measurementtesting only, do not connectinjector(s) electrically!

Start test and perform a visual check for leaks.Return flow bars have to bedisplayed corresponding to the number of injectors thatare connected.

When this doesn´t happen,check your measuring channel selection as wellas the connection of theKMA inlets.Make corrections as necessary.

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Test Steps

• Quantity Measurement

Connect injection chambers and electrical wires to the injector(s). Pay attention to hydraulical and electrical matching. Injected quantities are measured on the „odd channels“ (1, 3, 5, 7, 9 and 11),return flow quantities are measured on the „even channels“ (2,4, 6, 8 and 10)

Up to six CRI can be mounted to the test bench and tested simultaneously.CRIN are tested one at the time by using the appropriate high- and lowpressure adaptors.Refer to test set operating instruction for more information.

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Injector Testing

• Quantity MeasurementConnect injection chambersand electrical wires.

Start Test, check again for leaks.

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Test Sequence:

• Return Flow MeasurementA defective nozzle and/or defective valves and seals cancause a too high return flow quantity.

• Do not continue testing injectors with these presumeddefects, measuring results of the other injectors will beinfluenced.

• Perform a nozzle change on the injectors that had to be excluded from the testing.See chapter „Nozzle Change“ for further details.

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Test Sequence (Continued)

• Quantity test points and return flow rates have to correspond withthe matrix-chart on the next page.

• If not, the injector can not be repaired and needs to be substitutedwith a Bx unit or a new injector.

• A nozzle change can rectify the problem of a too high return flow rateof the injector.After the nozzle change, re-run the test of the injector.In case that the flow rate is still too high, the injector has a defect that can not be repaired in a service workshop.Substitute the injector with a Bx- or new unit.

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Injector Testing (Nozzle Change useful)

Q-Testpoint Return Flow Nozzle Change

X + Yes

+ + Yes+ X Yes

-/0 + Yes-/0 X Yes

At least 1Q-Testpointwithin range.Combinationsare possible



X = In Range, + = Too high, -/0 = Too low or zero

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Trouble Shooting Chart

• Q-Testpoint within range, return flow within range: Injector is good• Q-Testpoint within range, return flow too high: Nozzle Change• Q-Testpoint too high, return flow too high:: Nozzle change• Q-Testpoint too low and return flow too high: Nozzle change• Q-Testpoint too low and return flow within range: Nozzle change• Q-Testpoint to low and return flow too low: Injector defective

Other Combinations of Q-Testpoint and return flow rate results are possible, soa nozzle change may be useful.

Whenever a nozzle change was carried out, the injector has to be tested again.

After a nozzle change all Q-Testpoint and return flow measuring results have to bewithin range, otherwise replace injector with a Bx or new unit.

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Mounting Device for CRI and CRIN (0 986 610 130)

Protractors and Nut Adaptors

Lever with Spring-package for applyingnozzle Tie-Down Force

Adjustment Screwfor Tie-Down Force

Lower Clamping Bracketsfor Injectors

Height Adjustmentupper Clamping Brackets

Height Adjustment of Lever

Clamping Bracket for Vice Mounting


Shaft


Adjustable Reference-mark

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Nozzle Replacement, Working Steps

Mount the injector absolutely vertical into the mountingdevice:

Loosely mount the key-surface of the injector into thelower clamping brackets of the mounting device.

Attach, align and fasten the upper clamping bracket to the injector housing so that the injector is fixedexactly vertical in the mounting device.When this is done, fasten the lower clamping bracket.

Verify that the injector is still mounted absolutelyvertical.Repeat the procedure if necessary.

1

2


1 = Lower Clamping Brackets2 = Upper Clamping Brackets3 = Tie-Down Force Lever


3

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Nozzle Replacement, working steps (Continued)

• Place a collecting tray underneath the injector to catchdown falling parts

• Place nut adaptor on nozzle retaining nut

• Set and align lever for tie-down force.

• Apply tie-down force:Injector is mounted vertically into the mounting device,both upper and lower clamping bracket are fastened.Place body-fit sleeve on nozzle tip.


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Nozzle Replacement, working steps

Turn the adjustment screw for the tie-downforce until there is no gap between thetwo sleeves, see pictures,

Note: It is not necessary to mount theprotractor that can be seen on the left picture for this working step.


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Nozzle Replacement, Working steps

• Pre-set a torque wrench to 150 Nm• Unscrew the nozzle retaining nut with the torque wrench.• If the nozzle retaining nut can´t be loosened with

< 150 Nm, then the injector must not be repaired.Reason: Sealing surfaces can be damaged.In case the torque rate is higher, replace injector with a bx-unit ir a new one.

• Further unscrew the nozzle retaining nut by hand.

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Nozzle Replacement, working steps

• Cut back the tie-down force• Remove nozzle retaining nut• Remove nozzle, pay attention to eventually falling

parts!

• Visual check:Determine whether the nozzle locating pins are ofthe spiral- or cylindrical type.Note: Spiral type locating pins can´t be removedwithout applying great mounting forces,cylinder type locating pins can be pulled out withoutgreat force.

• An injector with spiral type locating pins must notbe repaired.Re-assemble the injector and replace it with a Bxunit or a new injector.


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Testing and Repair of CRI and CRINNozzle Replacement (Overview)

• Top picture, CRI1 with pressure pin:Remove locating pins, pressure pin, nozzle spring and adjustmentshim from the injector housing.

• Bottom picture, CRI 1 or CRI2 with nozzle guided valve piston (DGV):Remove locating pins, pressure pin (pill), guide sleeve, nozzle springand adjustment shim from the injector housing.Handle these parts with care since they, with the exception of the locatingpins, have to be reused in the same injector where they came out of.

• Clean the reusable parts and nozzle retaining nut thread of the partiallydisassembled injector in an ultrasonic bath.Mount the injector(s) into a self-made clamp and secure them fromtumbling or falling into the ultrasonic bath and place the reusable partsinto a suitable screen or strainer.Remove the injector(s) from the ultrasonic bath after 15 minutes,dry with clean compressed air.

• Inspect the injectors nozzle retaining nut thread, nozzle sealing surface,and the housing bore for damage by using an illuminated magnifying glass.



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Nozzle Replacement• Remove locating pins, pressure pin/DGV,

nozzle spring and adjustment shim. The nozzle, its retaining nut and the locating pins mustnot be reused, discard and substitute with new parts. Pressurepin/DGV, nozzle spring and adjustment shims are not available as spare parts. These parts have to be reused in the same injector where they came out of.

• The injectors nozzle retaining nut thread has to be thoroughly cleaned in an ultrasonic bath. Mount the injector(s) into a self-made clamping device and dipthem into the cleaning detergent for 15 minutesMake sure the injector(s) do not submerge.

• Remove the injectors from the bath and dry them with clean compressed air.Select new locating pins, nozzle and retaining nut from thespare parts list.

• Clean the sealing surfaces of both nozzle and injector in cir-cular movements with a vacuum pump.

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Nozzle Replacement

• Refer to the chapter „Visual Inspection“ for checking the metal surfaces of the injector body by using a lighted magnifying glass.

• Injectors with damaged surfaces must not be repaired,substitute with Bx- or new units.

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Soiled, corroded threads.Ultrasonic cleaning necessary.

Clean, undamaged thread


Visual inspection of retaining nut thread

The retaining nut thread of the injector body mustnot be damaged or soiled.Damaged and/or soiled threads lead to a faultymount of both nozzle and retaining nut.As a result, leak will occur.

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Nozzle Sealing Surface


Top right picture shows standard sealing surface inexcellent condition, injector can be repaired.

Bottom right picture shows damaged sealing surface.Injector can not be repaired.

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Top right picture shows „Maltese Cross Type“ sealingsurface in excellent condition.

Bottom right picture shows damaged sealing surface.Injector can not be repaired.Compare pictures on previous, the sealing surfacemust not show any damages.

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Top right picture shows „Butterfly Type“ sealingsurface in excellent condition.

Bottom right picture: The red coloured areas must not show any damages. Injectors with damages in this area can not be repaired.


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Visual Inspection of Bore Hole

The injectors bore hole must not show anydamages or corrosion.

Picture on top shows a bore hole in good condition.

The picture below shows a corroded bore hole.The injector must not be repaired.


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Nozzle Replacement

• Mount the cleaned and dried injector vertically intothe mounting device.

• Place adjustment shim, spring, DGC-sleeve (if available)and pressure pin correctly into the injector body.Make sure to reuse exactly the parts that came fromthe injector that is now reassembled.

• Insert new location pins into the injector housing.

The diameter of the location pin borehole is slightly smaller than the one for the supply to the nozzle.

• Mount one of the protractors to the new nozzle retaining nut.

• Place the cleaned new nozzle on the injector body,make sure the fuel supply bore hole(s) align properly.

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Nozzle replacement

• Hold nozzle down by hand and turn new nozzle retaining nut with attached protractor down.

• Place nut adaptor on nozzle retaining nut.• Apply tie-down force

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Nozzle Replacement

Mounting process of nozzle retaining nut (NRN)• Positioning: Using a torque wrench, fasten NRN with 5 Nm.• Pre-tightening: Continue tightening with specified torque rate.• Loosening: Turn NRN ccw by 120°.• Final tightening: Fasten NRN with 5 Nm.

Set protractor to 0°.Continue to turn NRN clockwise with specified angle rate.An exceeded torque range indicates a stiff moving retaining nut thread.

• Reduce tie-down force completely, take nut adaptor from NRN.• Take injector out of mounting device.• Test repaired injector(s) on the test bench.

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Nozzle ReplacementTorque- and angle rates CRI 1

Standard nozzle sealing surface, NRN-thread M 15 x 0,5 or M 17 x 0,75

Pre-tightening: 60 +/- 2 NmLoosening: 120°Positioning: 5 NmFinal tightening: 66° + 5°, -1° (M 15 x 0,5) 46° +/- 3° (M 17 x 0,75)Torque range: 33...50 Nm (M 15 x 0,5) 36...54 Nm (M 17 x 0,75)

Maltese Cross sealing surface, NRN-thread M 15 x 0,5 or M 17 x 0,75

Positioning: 5 NmPre-tightening: 60 +/- 2 NmLoosening: 120°Positioning: 5 NmFinal tightening: 53° +/- 3° (M 15 x 0,5) 40° +/- 3° (M 17 x 0,75)Torque range: 26...38 Nm (M 15 x 0,5) 32...50 Nm (M 17 x 0,75)

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Nozzle Replacement

Torque- and angle rates CRI 2

Butterfly sealing surface, NRN-thread M 15 x 0,5 or M 17 x 0,75

Pre-tightening: 40 +/- 4 Nm (M 15 x 0,5) 45+/- 4 Nm (M 17 x 0,75) Loosening: 120°Positioning: 5 Nm Final tightening: 60° +/-3° (M 15 x 0,5) 44° +/- 3° (M 17 x 0,75)Torque range: 26...45 Nm (M 15 x 0,5) 35...53 Nm (M 17 x 0,75)

Butterfly sealing surface, only BMW, NRN-thread M 15 x 0,5

Pre-tightening: 40 +/- 2 NmLoosening: 120°Positioning: 5 Nm2nd pre-tightening: 73° +/- 3°, torque range 25...60 NmLoosening: 90°Positioning: 5 NmFinal tightening: 60° +/- 3°, torque range 26...38 Nm

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Tightening torque- and angle rates for CRIN (0 445 120 xxx)

//DSM1Cummins0 445 120 018, 032

RL.N1DRST2DSM1RVI0 445 120 012, 013, 016, 017

/DRST3DSM3Iveco0 445 120 011, 036

//DSM4RVI0 445 120 009, 010,014, 015, 019, 020

/DRST2DSM4Duramax0 445 120 008

//DSM1Iveco/Cummins/CNH0 445 120 007

/DRST2DSM1MFTBC0 445 120 006

//DSM2RVI0 445 120 003, 004

/DRST1DSM1IVECO0 445 120 002

Return FittingHP-FittingRetaining NutVehicleInjektor No.

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Tightening torque- and angle rates for CRIN (0 445 120 xxx)

//DSM1Iveco0 445 120 028

//DSM1MAN0 445 120 030, 031, 044, 045

/DRST3DSM3VolvoPenta0 445 120 033 , 034, 051, 052

/DRST2DSM1Duramax0 445 120 027

//DSM1Ford Otosan0 445 120 025

Return FittingHP-FittingRetaining NutVehicleInjektor No.

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Nozzle ReplacementTorque- and angle rates CRIN with nozzle retaining nut (NRN) type DSM 1and 2

DSM 1 (NRN-thread M 19 x 0,75)

Pre-tightening: 55 Nm (50...90 Nm)Loosening: 95° (85...95°)Positioning: 5 NmFinal tightening: 45° (43...47°) with max. torque rate of 70Nm

DSM 2 (NRN-thread M 19 x 0,75, chamfered nozzle)

Pre-tightening: 55 Nm (50...60 Nm)Loosening: 90° (85...95°)Positioning: 5 NmFinal tightening: 45° (43...47°) with max. torque rate of 80 Nm

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Nozzle ReplacementTorque- and angle rates CRIN with nozzle retaining nut (NRN) type DSM 3 and 4





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Injector LeaksReplacement of high pressure fitting:

• Not possible with CRI/CRIN that feature secured threads (e.g. Daimler Chrysler).Refer to spare parts list!

• Clean the injector around the high pressure fitting by using a vacuum pump.• Mount the injector into a vice by using a v-block, unscrew old fitting with

a torque wrench.The loosening torque must not exceed 100 Nm.

• Take old high pressure fitting out of the injector housing.• Remove sealing shim.

Replacement of screwed-on return flow fitting on CRIN:• Not possible with permanently fixed return flow fitting!• Mount fitting into thread by hand.• Apply final torque rate of 2.5...3.5 Nm to the fitting

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Visual Inspection High Pressure Fitting


Damaged sealing surfaces can cause leaks.The used sealing shim may have small impression traces.Other damages, like burrs, are not tolerable because theycan become loose and cause further damage to the injector.

Note: Injectors for Daimler-Chrysler vehicles have secured threads, fittings can not be removed from the injector.

Injectors for commercial vehicles (CRIN) do not have sealingshims for the high pressure fitting.

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Top left picture:Thread in good condition

Right pictures:Damaged threads, no injector repair possible.Replace with Bx-or new unit.

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Left side pictures:Sealing surface for high pressurefitting in good condition.

Picture below:Damaged sealing surface, injector can´tbe repaired.

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Tightening torque rates for high pressure fittingWorking steps for CRI ( 0445 110 xxx)

• Apply a thin coat of clean oil to the new fitting.• Mount the new fitting with a new sealing shim (CRI only).

Tightening torque 40...44 Nm.

• After repair, run injector leak test on test.

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Tightening torque rates for high pressure fittingWorking steps for CRIN ( 0445 120 xxx)

Apply a thin coat of clean oil to the new fitting.

Fitting for 6 mm high pressure tube (DRST 1 und 3)

Pre-tightening: 50 Nm (45...55 Nm)Loosening: 90° (85...95°)Final tightening: 75 Nm (45...75 Nm)Angle control: 15° (13...17°), with max. torque rate of 70 Nm

Fitting for 8 mm high pressure tube (DRST 2)

Pre-tightening: 70 Nm (65...75 Nm)Loosening: 90° (85...95°)Final tightening: 93 Nm (60...93 Nm)Angle control: 20° (18...22°), with max. torque rate of 70 Nm

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After the repair work the injector(s) have to be tested dynamically on the test bench.

In case the measured quantities are not within specification, the injector has a defect that can not be repaired in service.Use a new injector or a Bx-unit as a substitute.

If all measurements are within specification, the injector can be remounted to the engine.

As an indication for the repair work, scratch a crossonto the key surface of each injector by using a scribe.

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After completing the re-instalment, run the engine until it has reached operating temperature, check for leaks.

Make another check for leaks after a test drive and perform an exhaustgas test.

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Devices, Tools and auxiliary equipment

• Mounting Device for CRI and CRIN 0 986 610 130• Mounting Sleeves for CRIN O-Rings Set of four sleeves 0 985 612 930

30.8 x 150 mm 0 986 612 93130.8 x 146 mm 0 986 612 93229.3 x 150 mm 0 986 612 93327,8 x 152 mm 0 986 612 934

• Torque Wrench, measuring range 0...25 Nm commercially available• Torque Wrench measuring range 25...100 Nm commercially available• Open-End bit 27 mm for torque wrench commercially available• Ultrasonic Cleaning Bath commercially available• Cleaning Detergent, e.g. Tickopur commercially available(Must contain ammonia, suitable for removal ofcorrosion and particulate matters)

• Clamping Device for injectors self made

• Commercially available mineral oil for mounting high pressurefittings, e.g.- Renolin MR 46 MC- Astron HVLP 46- alternatively engine oil 5 W 40

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Abbreviations

• DGV Nozzle Guided Valve Piston (Düsengeführter Ventilkolben)• DSM Nozzle Retaining Nut (Düsen Spannmutter)• IMA Injector Quantity Balancing for CRI (Injektor Mengen Abgleich)• NIMA Injector Quantity Balancing for CRIN (Nutzfahrzeug Injektor Mengenabgleich)• ISA Injector Voltage Balancing for CRI3 (Injektor Spannungs Abgleich) • CRI Common Rail Injector for Passenger Cars• CRI1, 2 Injector generations with typical features• CRI3 Common Rail injector with piezo actuator• CRS 845 Test set for testing Common-Rail high pressure pumps• CRIN Common Rail injector for commercial vehicles• CRIN1, 2 Injector generations for commercial vehicles with typical features• KMA Continuous Quantity Analysis (Kontinuierliche Mengen Analyse)

KMA 802 with PC in test benchKMA 822 with PC in separate trolley

• EPS 815 Injection test bench, base model