MANUAL - Bosch CRIN 2.0 and 3.0 Common Rail Injectors [PDF]

Zitiervorschau

MAKTEST, INC.

Service Manual Bosch CRIN 2.0 and 3.0 Common Rail Injectors 08.06.2010

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 Introduction to Servicing Bosch CRIN 2.0 and 3.0 Injectors ................................................................................ 1 Recommended Tool Set for Servicing CRIN 2.0 and 3.0 Common Rail Injectors ................................................ 1 Description of Components ................................................................................................................................. 5 Identifying CRIN 2.0 and CRIN3.0 .................................................................................................................... 6 Disassembling the Solenoid and the Control Valve Mechanism ......................................................................... 7 Disassembling the Nozzle .................................................................................................................................. 11 Assembling the Injector ..................................................................................................................................... 12 Assembling the High Pressure Seal ............................................................................................................... 12 Assembling Control Valve .............................................................................................................................. 15 Assembling Fixing Nut ................................................................................................................................... 16 Measuring and Setting Sealing Tolerance ..................................................................................................... 16 Measuring and Setting Air Gap...................................................................................................................... 18 Assembling the Solenoid ............................................................................................................................... 20 Assembling Nozzle ......................................................................................................................................... 21 Measuring Nozzle Lift ................................................................................................................................ 21 Assembling the Nozzle Holder ....................................................................................................................... 22

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Introduction to Servicing Bosch CRIN 2.0 and 3.0 Injectors Note: The following information is prepared for users in need to comprehend the methodology of repairing Bosch CRIN Common Rail Injector. There may be differences on various types of CRIN Injectors. Please use below instructions only as a reference, and apply the methodology of this repair to other types of Bosch CRIN Common Rail Injectors where possible.

Recommended Tool Set for Servicing CRIN 2.0 and 3.0 Common Rail Injectors Please see below the list of recommended tools for servicing Bosch CRIN 2.0 and 3.0 Common Rail Injectors. 1. KO1382 – Bosch CRI and CRIN 1.0 Repair Tool Set. FOTO 2. KO1579 – Bosch CRIN 2.0 and 3.0 Repair Tool Set a. KO1547 – Air Gap Measurement Tool. b. KO1548 – Control valve puller for CRIN2.0 and 3.0. c. KO1556 – Control Valve Assembly Tool for CRIN 2.0 and 3.0 d. BA1557 – Seal Assembly tool for CRIN2.0 and 3.0 e. MO1095 – Sealing Tolerance Measuring Tool FOTO

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3. KO1475 Clean Bench for Repairing Common Rail Injectors

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4. KO1560 Digital Torque Wrench

Additional Items for servicing: 1. OA1021 Digital Dial Gauge 0-10 mm with 0.01 mm resolution.

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Description of Components 1 2 3 4 5 6 7 8 9 10 11 12

Solenoid Solenoid Retainer Solenoid Air Gap Adjustment Washer Solenoid Spring Solenoid Spring Adjustment Washer Spindle Magnet Plate Spring Magnet Plate Spindle Sealing Adjustment Washer Fixing Nut Injector Body Ball Housing

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Ball High Pressure Seal High Pressure Seal Support Ring Control Valve Control Pin Nozzle Spring Adjustment Washer Nozzle Spring Guide for Nozzle Lift Adjustment Shim Nozzle Shim Adjustment Shim Nozzle Pins Nozzle Nozzle Holder

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Identifying CRIN 2.0 and CRIN3.0

CRIN 2.0

CRIN 3.0

CRIN 2.0 has the valve armature-spindle bolted to the magnet plate. It can be removed as a single piece only. Additionally there is no spring underneath the armature to lift up the magnet plate, as it is bolted to spindle. CRIN3.0 has the valve armature in pieces. The spindle and the magnet plate are separate and there is a need for a spring to lift up the magnet plate during the non-injection time, to preserve the air gap throughout the operation.

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Disassembling the Solenoid and the Control Valve Mechanism WARNING! Clean the complete injector in the ultrasonic cleaning tank before disassembling the injector.

Follow below instructions to disassemble the solenoid and the control valve mechanism. Use appropriate tool or spanner to remove the Solenoid.

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Remove solenoid retainer and the solenoid. Carefully pull the solenoid up and do not let the spring and the washer to fall out.

Remove the spring and the adjustment washer.

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Remove the spindle (for 2.0 spindle and magnet plate together). Check that the ball housing and the ball is not coming off at the tip of the spindle.

Remove the Magnet Plate (CRIN3.0 only)

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Remove the Support Spring (CRIN 3.0 only); Sealing Tolerance adjustment washer; Ball Housing and Ball

Release the fixing nut and remove it using the appropriate insert.

Remove the control valve using KO1548 control valve puller.

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Remove the high pressure seal and its support ring.

Disassembling the Nozzle Make sure the clamp the injector firmly to avoid damaging the nozzle pins. Use the appropriate size socket adapter to be able to grasp the nozzle holder better. Use a long wrench to be able to exert force to release the nozzle holder.

Remove the nozzle, and make sure not to drop any small parts from inside the injector.

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Remove the Nozzle Lift Adjustment Shim, Shim Guide, Nozzle Spring and Spring Tension Adjustment Shim.

Assembling the Injector Assembling the High Pressure Seal High Pressure Seal is one of the most critical assembly procedures. Make sure follow the procedure completely; otherwise the seal life will be reduced. Use the KO1557 Seal Assembly tool and the dummy (metal) seal to set the seal depth on the tool. Place the dummy seal on the tool tip and insert the tool into the injector body.

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Screw in KO1557 with the dummy seal, leave it hand tight.

Push the shaft at the center to place the seal in the injector. Tighten the screw on the top to fix the center shaft at the correct seal depth length.

Push the setting knob on the center shaft to touch the screw in housing and tighten the screw to fix its position on the center shaft. Release the screw on the housing the let the center shaft move out of the injector with the setting knob fixed.

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Disassemble KO1557 off the injector body, place the NEW seal support with its curved seat facing the high pressure seal on KO1557 center shaft tip.

Hide the tip of the center shaft where the seal and the support is, inside KO1557 body and screw in the injector body. Gently push the center shaft to place the seal.

Note The same setting can be used to assemble same type of injectors. The depth setting does not change for the same injector numbers.

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Assembling Control Valve Place the control pin with its thinner end facing nozzle side. Place the Control Valve, making sure that the control pin is placed inside the control valve.

Mount KO1556 Control Valve Assembly tool on the injector body. Note that the KO1556 center shaft is fully extracted. Turn the center shaft clockwise to start pushing the control valve down. Do not force to tighten too much.

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Assembling Fixing Nut Assemble the fixing nut in the injector. Tighten fixing nut according to torque values and tightening procedure explained below.

Note Pre-tightening torque 70 Nm Release >45° Apply 23 Nm Finish (11°-15°) should not exceed 75 Nm.

Measuring and Setting Sealing Tolerance Assemble the dial gauge to MO1095 sealing tolerance measuring tool with the thin extension. Reset the dial gauge to zero on a flat surface. Place the ball and the ball holder carefully.

Place the tip of the thin extension into the center hole of the fixing nut.

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Place the Sealing Tolerance adjustment washer. Measure the depth of the ball housing from the assembly surface. Note this depth.

Change the extension with the thick end extension. Reset the dial gauge on a flat surface again.

Assemble the spindle and the magnet plate.

CRIN 2.0

CRIN 3.0

Measure the extension tip of the spindle tip. Note the Length.

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Note Sealing tolerance is |Depth|-|Length|. Sealing tolerance must be min 0.03 mm. Increase the thickness of the adjustment washer to decrease the sealing tolerance. Decrease the thickness of the adjustment washer to increase the sealing tolerance.

Measuring and Setting Air Gap Make sure to remove the air gap adjustment washer on the solenoid. Place the short extension to KO1547. Reset the Dial gauge on a flat surface.

Measure the solenoid length. Note the Length.

Replace the extension with the long one. Reset the dial gauge on a flat surface. Carefully place the magnet plate and the spindle in the injector.

Make sure to place the air gap adjustment washer in the injector. Measure the depth of the magnet plate surface with respect to the assembly surface. Note the Depth.

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Note Air Gap is |Depth| - |Length| Air Gap should be measured 0.12-0.16 mm.

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Assembling the Solenoid Check the o-ring on the solenoid and replace if necessary. Make sure that the air gap and the sealing tolerance is set correctly. Place the solenoid in the injector and place the solenoid retainer over the solenoid. Tighten the solenoid retainer according to procedure and tightening torques specified below. Note Tightening torques for different size retaining nuts are different. Make sure apply the correct thightening torques for correct retaining nuts. Tightening Torques for retaining nut integrated with the solenoid: Pre-tightening 25 Nm. Release >45° Apply 7 Nm. Final tightening 14°-18°; final torque must reach min 36 Nm

Tightening Torques for retaining nut 28mm: Pre-tightening 25 Nm. Release >45° Apply 7 Nm. Final tightening 10°-14°; final torque must reach min 36 Nm Tightening Torques for retaining nut 27mm: Pre-tightening 25 Nm. Release >45° Apply 7 Nm. Final tightening 14°-18°; final torque must reach min 34 Nm Tightening Torques for retaining nut 30mm: Pre-tightening 25 Nm. Release >45° Apply 7 Nm. Final tightening 28°-32°; final torque must reach min 36 Nm

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Assembling Nozzle Place the nozzle spring tension adjustment washer first and then nozzle spring. Place the shim guide for nozzle lift, with its bigger hole facing up. Place the Nozzle lift adjustment shim inside the guide.

Measuring Nozzle Lift Assemble the dial gauge to KO1379 with the thin extension. Reset the dial gauge on a flat surface. Place KO1379 on the injector nozzle end and aim the thin tip to sit on the adjustment shim in the guide.

Measure the Nozzle Lift, making sure that KO1379 sits on the surface evenly.

Note Nozzle Lift varies depending on the nozzle numbers. Make sure to record every injectors nozzle lift into TK1026 database. Service Information Card (SIC) database is developped to store all assembly dimensions for Common Rail Injectors.

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Assembling the Nozzle Holder Place the nozzle on the injector tip. Place the Nozzle holder over the nozzle and slightly tighten with your hand to prevent it from dropping. Place the socket adaptor for nozzle holder over the nozzle holder. Clamp the nozzle to avoid damaging the pins.

Tighten the nozzle holder accroding to below specified procedure and tigthening torques. Note Pre-tightening torque 60 Nm Release >45° Apply 5 Nm Finish tightening between 43°-47°, tightening torque should be min 90Nm.

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