cri / crin defect catalogue 1 department | 11.07.2006 | © all rights, including patent...

1

CRI / CRIN Defect Catalogue

Department | 11.07.2006 | © All rights, including patent applications, reserved by Robert Bosch GmbH. All rights of disposal, including copyright and right of distribution, reserved.

2


AA/ASA | 11.07.2006 | © All rights reserved by Robert Bosch GmbH, including patent applications. All rights of disposal, including copyright and right of distribution, reserved.

Test Procedure

Indication of incompletevehicle information

In warranty period

CRI/CRIN

Product information complete

1

Vehicle information complete

NoYes Reject

NoYes Reject

NoYes Reject

Indication of incomplete product information

Indication of expired warranty period

Bosch product

NoYes Reject Indication of third-party

product

Page 3

Page 4

3


AA/ASA | 11.07.2006 | © All rights reserved by Robert Bosch GmbH, including patent applications. All rights of disposal, including copyright and right of Distribution, reserved.

Test Procedure

Visual check

Dismantling

Test bench audit

Further test steps:

1

4



Product Information

Part number

Complete product

FD

Purchase date

Failure date

5



Vehicle Information

Chassis numberEngine number

First registrationDate of sale

Vehicle fault code(if available)

Vehicle manufacturerEngine manufacturer

Vehicle model

Mileage

6



Visual Inspection

Indication of mechanical damage

Visual inspection for mechanical damage

Visual inspection for outside intervention

RejectionYes

No

Yes

NoRejection Indication of outside

intervention

2

7



Visual Inspection

Visual inspection for mechanically cleaned,

brushed injectors

Indication of incorrect service center procedure

Yes

NoRejection

Visual inspection for thermal overload of

injector

Yes

NoRejection

Indication of thermal Overload, check engine for

consequential damage

Ultrasonic cleaning

of injector

2

8



Test Bench Audit

Test with Bosch test values on Bosch

EPS 815 test bench

Ultrasonic cleaning

of injector

DismantlingNo

YesInjector OK

No warranty case

9



Dismantling

Diagnosis of individual parts Evaluation against fault

symptoms catalogue

Acknowledge warranty

Observe storage periods for spare parts

Dismantle injectorin line with ESI instructions

Ultrasonic cleaning of

individual part

No

Yes

Warranty caseRejection Reference to fault

symptoms catalogue

10


Abteilung | 18.09.2006 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Automotive Aftermarket

Common Rail Injector (Passenger Car + Commercial Vehicle) Complaint

Poor performance Black smoke

Symptoms Combustion residue on outside of

injector Possible cause

Injector incorrectly installed (tightened or twisted on one side)

No sealing ring Inadequate tightening torque when

installed

Warranty decision: No warranty claim. No material or manufacturing fault

11







injector Sealing ring compressed on one side

Possible cause Injector incorrectly installed (tightened

or twisted on one side) No sealing ring Inadequate tightening torque when

installed Warranty decision:

No warranty claim. No material or manufacturing fault

12







injector Escaping gas


or twisted on one side) No sealing ring Inadequate tightening torque angle


13




Complaint Poor performance Black smoke


injector Possible cause


No sealing ring Inadequate tightening torque angle


Common Rail Injector (Passenger Car + Commercial Vehicle)

14






Symptoms Combustion residue on one side of

copper sealing ring Sealing ring compressed


or twisted on one side) Injector incorrectly installed (tightening

torque too high) Warranty decision:


New Not OK OK

15





Poor performance Idling problems (vibration) Combustion noise (diesel knock)

Symptoms Thermal overload Combustion residue (coking) on tip of

nozzle Possible cause

Diesel tuning Incorrect or non-approved additives in

fuel Engine oil in intake system Oil thinning Biodiesel


16






Symptoms Thermal overload Injection bore burnt out Some combustion residue on nozzle

cone and shaft Possible cause

Diesel tuning Incorrect or non-approved additives in

fuel Engine oil in intake system, sealing

problems Oil thinning


17




Complaint Poor performance Idling problems (vibration) Combustion noise (diesel knock)

Symptoms Thermal overload Injection bore burnt out

Possible cause Diesel tuning Incorrect or non-approved additives in





18






Symptoms Thermal overload Nozzle does not seal Nozzle tip melted





19






Symptoms Thermal overload Nozzle tip melted





20






Symptoms Thermal overload Nozzle tip melted Aluminum deposits on nozzle shaft





21




Complaint Poor performance Idling problems (vibration) Combustion noise (diesel knock)

Symptoms Thermal overload Aluminium deposits on nozzle shaft






22






Symptoms Thermal overload Aluminium deposits on nozzle shaft





23






Symptoms Thermal overload Surface severely scarred Blue tarnish on nozzle shaft





24




Complaint Poor performance (vehicle)

Symptoms Injection nozzle hole diameter

constricted Possible cause

Injector cleaned improperly (mechanically, wire brush)



25





Poor performance (vehicle)

Symptoms Mechanical damage to injector

Possible cause Injector cleaned improperly, evidence of

brushing on nozzle body and union nut


26





Poor performance (vehicle)

Symptoms Mechanical damage to injector

Possible cause Foreign parts in combustion chamber


27




Complaint Poor performance Start problems

Symptoms Thermal overload Nozzle needle seat worn Marked impression of injection holes on

nozzle needle Possible cause

Incorrect or non-approved additives in fuel

Engine oil in intake system, sealing problems

Oil thinning Bio-diesel



28





Poor performance Start problems

Symptoms Thermal overload Nozzle needle broken off Nozzle needle melted

Possible cause Incorrect or non-approved additives in


problems Oil thinning Bio-diesel


29





Idling problems (vibration) Combustion noise (diesel knock)

Symptoms Wear on one side of nozzle needle shaft.

Possible cause


Ultra fine particles in fuel Incorrect assembly sequence (CRIN)


30




Complaint Idling problems (vibration) Combustion noise (diesel knock)


Possible cause





31






Possible cause





32






Symptoms Wear on one side of nozzle needle shaft

combined with sealing ring compressed on one side


or twisted on one side) Ultra fine particles in fuel Incorrect assembly sequence (CRIN)


33






Symptoms Circumferential wear on valve piston

Possible cause Poor, abrasive fuel (particles) Poor, inadequate filtration


34









35









36






Symptoms Circumferential wear on distributor

piston



37





Poor performance Engine running out of true Combustion noise (diesel knock)

Symptoms Oil deposits in interior of CRI Valve piston or nozzle needle sluggish

Possible cause Engine oil in fuel system Leak in engine oil lubricated CP Leak on fuel return side of cylinder head

(CRIN) Warranty decision:


38






Symptoms Oil deposits in edge type filter Valve piston or nozzle needle sluggish

Possible cause Engine oil in fuel system Leak in engine oil lubricated CP Leak on fuel return side of cylinder head

(CRIN) Warranty decision:


39






Symptoms Deposits in interior of CRI Valve piston or nozzle needle sluggish

Possible cause Engine oil in fuel system Poor fuel Incorrect or non-approved additives in

fuel Warranty decision:


40







Possible cause Engine oil in fuel system Poor fuel Incorrect or non-approved additives in

fuel Warranty decision:


41





Poor starting performance Poor performance Engine running out of true


Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality

or filter service life exceeded Warranty decision:


42










43










44










45










46










47










48






Symptoms Edge type filter corroded Nozzle needle corroded




49





Poor performance Symptoms

Nozzle needle corroded Edge type filter corroded




50





Start problems Engine cuts out during journey Poor performance

Symptoms High-pressure sealing ring worn Return quantity too high

Possible cause Old sealing ring design, modification

introduced at beginning of 2004 Support ring assembly error

Warranty decision: Warranty case

Medium

Severe

51





Start problems Engine cuts out during journey Poor performance

Symptoms High-pressure sealing ring worn Return quantity too high

Possible cause Old sealing ring design, modification

introduced at beginning of 2004 Support ring assembly error

Warranty decision: Warranty case

Medium

Severe

52





Harsh combustion noise (diesel knock) Start problems

Symptoms Foreign particles in interior of injector

(blocked inlet hole, cellulose, filter particles)

Possible cause Poor, inadequate filtration Filter element contaminated with

loose particles Incorrect filter installation


53





Harsh combustion noise (diesel knock) Start problems

Symptoms Foreign particles in interior of injector

(packing film in inlet hole) Possible cause

Poor, inadequate filtration Filter element contaminated with

loose particles Incorrect filter installation Dirt present when installing injector or

lead


54





Complaint Harsh combustion noise (diesel knock) Start problems

Symptoms Steel particles or high-pressure

sealing ring splinters in interior of injector

Possible cause Splinters sheared off from high-

pressure sealing ring (assembly error) Field repair concept error

Warranty decision: Warranty for new and BX items. For repaired injector, workshop is responsible.

55





Complaint Poor performance Start problems No injection to this cylinder

Symptoms Steel particles in interior of injector

Possible cause Assembly error Field repair concept error

Warranty decision: Warranty for new and BX items. For repaired injector, workshop is responsible.

56





Complaint Poor performance Start problems Idling problems (vibration) Engine cuts out during journey Return quantity too high

Symptoms Erosion wear on valve piece ball seat



57





Poor performance Start problems Idling problems (vibration) Engine cuts out during journey Return quantity too high

Symptoms Erosion wear on valve piece ball seat



cri / crin defect catalogue 1 department | 11.07.2006 | © all rights, including patent...

Documents