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
CRI / CRIN Defect Catalogue
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
CRI / CRIN Defect Catalogue
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
CRI / CRIN Defect Catalogue
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.
Product Information
Part number
Complete product
FD
Purchase date
Failure date
5
CRI / CRIN Defect Catalogue
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.
Vehicle Information
Chassis numberEngine number
First registrationDate of sale
Vehicle fault code(if available)
Vehicle manufacturerEngine manufacturer
Vehicle model
Mileage
6
CRI / CRIN Defect Catalogue
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.
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
CRI / CRIN Defect Catalogue
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.
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
CRI / CRIN Defect Catalogue
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 Bench Audit
Test with Bosch test values on Bosch
EPS 815 test bench
Ultrasonic cleaning
of injector
DismantlingNo
YesInjector OK
No warranty case
9
CRI / CRIN Defect Catalogue
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.
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
CRI / CRIN Defect Catalogue
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
CRI / CRIN Defect Catalogue
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 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
CRI / CRIN Defect Catalogue
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 Escaping gas
Possible cause Injector incorrectly installed (tightened
or twisted on one side) No sealing ring Inadequate tightening torque angle
Warranty decision: No warranty claim. No material or manufacturing fault
13
CRI / CRIN Defect Catalogue
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
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 angle
Warranty decision: No warranty claim. No material or manufacturing fault
Common Rail Injector (Passenger Car + Commercial Vehicle)
14
CRI / CRIN Defect Catalogue
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 one side of
copper sealing ring Sealing ring compressed
Possible cause Injector incorrectly installed (tightened
or twisted on one side) Injector incorrectly installed (tightening
torque too high) Warranty decision:
No warranty claim. No material or manufacturing fault
New Not OK OK
15
CRI / CRIN Defect Catalogue
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 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
Warranty decision: No warranty claim. No material or manufacturing fault
16
CRI / CRIN Defect Catalogue
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 Idling problems (vibration) Combustion noise (diesel knock)
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
Warranty decision: No warranty claim. No material or manufacturing fault
17
CRI / CRIN Defect Catalogue
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
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
fuel Engine oil in intake system, sealing
problems Oil thinning
Warranty decision: No warranty claim. No material or manufacturing fault
Common Rail Injector (Passenger Car + Commercial Vehicle)
18
CRI / CRIN Defect Catalogue
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 Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Thermal overload Nozzle does not seal Nozzle tip melted
Possible cause Diesel tuning Incorrect or non-approved additives in
fuel Engine oil in intake system, sealing
problems Oil thinning
Warranty decision: No warranty claim. No material or manufacturing fault
19
CRI / CRIN Defect Catalogue
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 Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Thermal overload Nozzle tip melted
Possible cause Diesel tuning Incorrect or non-approved additives in
fuel Engine oil in intake system, sealing
problems Oil thinning
Warranty decision: No warranty claim. No material or manufacturing fault
20
CRI / CRIN Defect Catalogue
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 Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Thermal overload Nozzle tip melted Aluminum deposits on nozzle shaft
Possible cause Diesel tuning Incorrect or non-approved additives in
fuel Engine oil in intake system, sealing
problems Oil thinning
Warranty decision: No warranty claim. No material or manufacturing fault
21
CRI / CRIN Defect Catalogue
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
Complaint Poor performance Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Thermal overload Aluminium deposits on nozzle shaft
Possible cause Diesel tuning Incorrect or non-approved additives in
fuel Engine oil in intake system, sealing
problems Oil thinning
Warranty decision: No warranty claim. No material or manufacturing fault
Common Rail Injector (Passenger Car + Commercial Vehicle)
22
CRI / CRIN Defect Catalogue
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 Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Thermal overload Aluminium deposits on nozzle shaft
Possible cause Diesel tuning Incorrect or non-approved additives in
fuel Engine oil in intake system, sealing
problems Oil thinning
Warranty decision: No warranty claim. No material or manufacturing fault
23
CRI / CRIN Defect Catalogue
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 Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Thermal overload Surface severely scarred Blue tarnish on nozzle shaft
Possible cause Diesel tuning Incorrect or non-approved additives in
fuel Engine oil in intake system, sealing
problems Oil thinning
Warranty decision: No warranty claim. No material or manufacturing fault
24
CRI / CRIN Defect Catalogue
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
Complaint Poor performance (vehicle)
Symptoms Injection nozzle hole diameter
constricted Possible cause
Injector cleaned improperly (mechanically, wire brush)
Warranty decision: No warranty claim. No material or manufacturing fault
Common Rail Injector (Passenger Car + Commercial Vehicle)
25
CRI / CRIN Defect Catalogue
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 (vehicle)
Symptoms Mechanical damage to injector
Possible cause Injector cleaned improperly, evidence of
brushing on nozzle body and union nut
Warranty decision: No warranty claim. No material or manufacturing fault
26
CRI / CRIN Defect Catalogue
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 (vehicle)
Symptoms Mechanical damage to injector
Possible cause Foreign parts in combustion chamber
Warranty decision: No warranty claim. No material or manufacturing fault
27
CRI / CRIN Defect Catalogue
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
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
Warranty decision: No warranty claim. No material or manufacturing fault
Common Rail Injector (Passenger Car + Commercial Vehicle)
28
CRI / CRIN Defect Catalogue
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 Start problems
Symptoms Thermal overload Nozzle needle broken off Nozzle needle melted
Possible cause Incorrect or non-approved additives in
fuel Engine oil in intake system, sealing
problems Oil thinning Bio-diesel
Warranty decision: No warranty claim. No material or manufacturing fault
29
CRI / CRIN Defect Catalogue
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
Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Wear on one side of nozzle needle shaft.
Possible cause
Injector incorrectly installed (tightened or twisted on one side)
Ultra fine particles in fuel Incorrect assembly sequence (CRIN)
Warranty decision: No warranty claim. No material or manufacturing fault
30
CRI / CRIN Defect Catalogue
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
Complaint Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Wear on one side of nozzle needle shaft.
Possible cause
Injector incorrectly installed (tightened or twisted on one side)
Ultra fine particles in fuel Incorrect assembly sequence (CRIN)
Warranty decision: No warranty claim. No material or manufacturing fault
Common Rail Injector (Passenger Car + Commercial Vehicle)
31
CRI / CRIN Defect Catalogue
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
Complaint Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Wear on one side of nozzle needle shaft.
Possible cause
Injector incorrectly installed (tightened or twisted on one side)
Ultra fine particles in fuel Incorrect assembly sequence (CRIN)
Warranty decision: No warranty claim. No material or manufacturing fault
Common Rail Injector (Passenger Car + Commercial Vehicle)
32
CRI / CRIN Defect Catalogue
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
Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Wear on one side of nozzle needle shaft
combined with sealing ring compressed on one side
Possible cause Injector incorrectly installed (tightened
or twisted on one side) Ultra fine particles in fuel Incorrect assembly sequence (CRIN)
Warranty decision: No warranty claim. No material or manufacturing fault
33
CRI / CRIN Defect Catalogue
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 Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Circumferential wear on valve piston
Possible cause Poor, abrasive fuel (particles) Poor, inadequate filtration
Warranty decision: No warranty claim. No material or manufacturing fault
34
CRI / CRIN Defect Catalogue
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 Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Circumferential wear on valve piston
Possible cause Poor, abrasive fuel (particles) Poor, inadequate filtration
Warranty decision: No warranty claim. No material or manufacturing fault
35
CRI / CRIN Defect Catalogue
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 Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Circumferential wear on valve piston
Possible cause Poor, abrasive fuel (particles) Poor, inadequate filtration
Warranty decision: No warranty claim. No material or manufacturing fault
36
CRI / CRIN Defect Catalogue
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
Idling problems (vibration) Combustion noise (diesel knock)
Symptoms Circumferential wear on distributor
piston
Possible cause Poor, abrasive fuel (particles) Poor, inadequate filtration
Warranty decision: No warranty claim. No material or manufacturing fault
37
CRI / CRIN Defect Catalogue
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 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:
No warranty claim. No material or manufacturing fault
38
CRI / CRIN Defect Catalogue
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 Engine running out of true Combustion noise (diesel knock)
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:
No warranty claim. No material or manufacturing fault
39
CRI / CRIN Defect Catalogue
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 Engine running out of true Combustion noise (diesel knock)
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:
No warranty claim. No material or manufacturing fault
40
CRI / CRIN Defect Catalogue
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 Engine running out of true Combustion noise (diesel knock)
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:
No warranty claim. No material or manufacturing fault
41
CRI / CRIN Defect Catalogue
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 starting performance Poor performance Engine running out of true
Symptoms Deposits in interior of CRI Valve piston or nozzle needle sluggish
Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality
or filter service life exceeded Warranty decision:
No warranty claim. No material or manufacturing fault
42
CRI / CRIN Defect Catalogue
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 starting performance Poor performance Engine running out of true
Symptoms Deposits in interior of CRI Valve piston or nozzle needle sluggish
Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality
or filter service life exceeded Warranty decision:
No warranty claim. No material or manufacturing fault
43
CRI / CRIN Defect Catalogue
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 starting performance Poor performance Engine running out of true
Symptoms Deposits in interior of CRI Valve piston or nozzle needle sluggish
Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality
or filter service life exceeded Warranty decision:
No warranty claim. No material or manufacturing fault
44
CRI / CRIN Defect Catalogue
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 starting performance Poor performance Engine running out of true
Symptoms Deposits in interior of CRI Valve piston or nozzle needle sluggish
Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality
or filter service life exceeded Warranty decision:
No warranty claim. No material or manufacturing fault
45
CRI / CRIN Defect Catalogue
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 starting performance Poor performance Engine running out of true
Symptoms Deposits in interior of CRI Valve piston or nozzle needle sluggish
Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality
or filter service life exceeded Warranty decision:
No warranty claim. No material or manufacturing fault
46
CRI / CRIN Defect Catalogue
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 starting performance Poor performance Engine running out of true
Symptoms Deposits in interior of CRI Valve piston or nozzle needle sluggish
Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality
or filter service life exceeded Warranty decision:
No warranty claim. No material or manufacturing fault
47
CRI / CRIN Defect Catalogue
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 starting performance Poor performance Engine running out of true
Symptoms Deposits in interior of CRI Valve piston or nozzle needle sluggish
Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality
or filter service life exceeded Warranty decision:
No warranty claim. No material or manufacturing fault
48
CRI / CRIN Defect Catalogue
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 starting performance Poor performance Engine running out of true
Symptoms Edge type filter corroded Nozzle needle corroded
Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality
or filter service life exceeded Warranty decision:
No warranty claim. No material or manufacturing fault
49
CRI / CRIN Defect Catalogue
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 Symptoms
Nozzle needle corroded Edge type filter corroded
Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality
or filter service life exceeded Warranty decision:
No warranty claim. No material or manufacturing fault
50
CRI / CRIN Defect Catalogue
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
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
CRI / CRIN Defect Catalogue
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
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
CRI / CRIN Defect Catalogue
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
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
Warranty decision: No warranty claim. No material or manufacturing fault
53
CRI / CRIN Defect Catalogue
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
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
Warranty decision: No warranty claim. No material or manufacturing fault
54
CRI / CRIN Defect Catalogue
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 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
CRI / CRIN Defect Catalogue
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 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
CRI / CRIN Defect Catalogue
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 Start problems Idling problems (vibration) Engine cuts out during journey Return quantity too high
Symptoms Erosion wear on valve piece ball seat
Possible cause Poor, abrasive fuel (particles) Poor, inadequate filtration
Warranty decision: No warranty claim. No material or manufacturing fault
57
CRI / CRIN Defect Catalogue
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 Start problems Idling problems (vibration) Engine cuts out during journey Return quantity too high
Symptoms Erosion wear on valve piece ball seat
Possible cause Poor, abrasive fuel (particles) Poor, inadequate filtration
Warranty decision: No warranty claim. No material or manufacturing fault