Defect Catalog

CRI / CRIN Defect Catalogue
1 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.
Test Procedure
CRI/CRIN
Bosch product
No
Reject Indication of third-party
Yes product
Product information complete Page 3
No Indication of incomplete
Yes Reject
product information
Vehicle information complete Page 4
No Indication of incomplete
Yes Reject
vehicle information
In warranty period
No Indication of expired
Yes Reject
warranty period
2 AA/ASA | 11.07.2006 | © All rights reserved by Robert Bosch GmbH, including patent applications.
Test Procedure
Further test steps:
Visual check
Test bench audit
Dismantling
All rights of disposal, including copyright and right of Distribution, reserved.
Product Information
Part number
Complete product
FD
Purchase date
Failure date
Vehicle Information
Vehicle manufacturer First registration

Engine manufacturer Date of sale
Vehicle fault code

Vehicle model
(if available)
Chassis number Mileage

Engine number
Visual Inspection
Visual inspection for

mechanical damage
Yes
Rejection Indication of mechanical
damage
No

outside intervention
Yes
Indication of outside
Rejection
intervention
No
Visual Inspection

mechanically cleaned,
brushed injectors
Yes Indication of incorrect

Rejection
service center procedure
No
thermal overload of
injector
Yes Indication of thermal

Rejection Overload, check engine for
consequential damage
No
Ultrasonic
cleaning
of injector
Test Bench Audit
Ultrasonic
cleaning
of injector
Test with Bosch test values

on Bosch
EPS 815 test bench
No
Dismantling
Yes
Injector OK
No warranty case
Dismantling
Dismantle injector
in line with ESI instructions
Ultrasonic
cleaning of
individual part
Diagnosis of individual parts

Evaluation against fault
symptoms catalogue
Warranty case No Reference to fault

Rejection
symptoms catalogue
Yes
Acknowledge warranty
Observe storage periods for spare parts
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
Automotive Aftermarket
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.
 Complaint
 Black smoke
 Symptoms
 Sealing ring compressed on one side
 Possible cause
 No sealing ring
 Inadequate tightening torque when
installed
No warranty claim.
 Complaint
 Black smoke
 Symptoms
 Escaping gas
 Possible cause
 No sealing ring
 Inadequate tightening torque angle
No warranty claim.
 Complaint
 Black smoke
 Symptoms
 Possible cause
 No sealing ring
 Inadequate tightening torque angle
No warranty claim.
 Complaint
 Black smoke
 Symptoms
 Combustion residue on one side of copper
sealing ring
 Sealing ring compressed
 Possible cause
 Injector incorrectly installed (tightening torque
too high)
Not OK OK New
No warranty claim.
 Complaint
 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
No warranty claim.
 Complaint
 Symptoms
 Injection bore burnt out
 Some combustion residue on nozzle cone
and shaft
 Possible cause
 Diesel tuning
 Engine oil in intake system, sealing problems
 Oil thinning
No warranty claim.
 Complaint
 Symptoms
 Injection bore burnt out
 Possible cause
 Diesel tuning
 Oil thinning
No warranty claim.
 Complaint
 Symptoms
 Nozzle does not seal
 Nozzle tip melted
 Possible cause
 Diesel tuning
 Oil thinning
No warranty claim.
 Complaint
 Symptoms
 Possible cause
 Diesel tuning
 Oil thinning
No warranty claim.
 Complaint
 Symptoms
 Aluminum deposits on nozzle shaft
 Possible cause
 Diesel tuning
 Oil thinning
No warranty claim.
 Complaint
 Symptoms
 Aluminium deposits on nozzle shaft
 Possible cause
 Diesel tuning
 Oil thinning
No warranty claim.
 Complaint
 Symptoms
 Aluminium deposits on nozzle shaft
 Possible cause
 Diesel tuning
 Oil thinning
No warranty claim.
 Complaint
 Symptoms
 Surface severely scarred
 Blue tarnish on nozzle shaft
 Possible cause
 Diesel tuning
 Oil thinning
No warranty claim.
 Complaint
 Poor performance (vehicle)
 Symptoms
 Injection nozzle hole diameter constricted
 Possible cause
 Injector cleaned improperly
(mechanically, wire brush)
No warranty claim.
 Complaint
 Symptoms
 Mechanical damage to injector
 Possible cause
 Injector cleaned improperly, evidence of
brushing on nozzle body and union nut
No warranty claim.
 Complaint
 Symptoms
 Mechanical damage to injector
 Possible cause
 Foreign parts in combustion chamber
No warranty claim.
 Complaint
 Start problems
 Symptoms
 Nozzle needle seat worn
 Marked impression of injection holes on
nozzle needle
 Possible cause
 Oil thinning
 Bio-diesel
No warranty claim.
 Complaint
 Start problems
 Symptoms
 Nozzle needle broken off
 Nozzle needle melted
 Possible cause
 Oil thinning
 Bio-diesel
No warranty claim.
 Complaint
 Symptoms
 Wear on one side of nozzle needle shaft.
 Possible cause
 Ultra fine particles in fuel
 Incorrect assembly sequence (CRIN)
No warranty claim.
 Complaint
 Symptoms
 Possible cause
No warranty claim.
 Complaint
 Symptoms
 Possible cause
No warranty claim.
 Complaint
 Symptoms
 Wear on one side of nozzle needle shaft
combined with sealing ring compressed on
one side
 Possible cause
No warranty claim.
 Complaint
 Symptoms
 Circumferential wear on valve piston
 Possible cause
 Poor, abrasive fuel (particles)
 Poor, inadequate filtration
No warranty claim.
 Complaint
 Symptoms
 Possible cause
No warranty claim.
 Complaint
 Symptoms
 Possible cause
No warranty claim.
 Complaint
 Symptoms
 Circumferential wear on distributor piston
 Possible cause
No warranty claim.
 Complaint
 Engine running out of true
 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)
No warranty claim.
 Complaint
 Symptoms
 Oil deposits in edge type filter
 Possible cause
 Leak in engine oil lubricated CP
 Leak on fuel return side of cylinder head
(CRIN)
No warranty claim.
 Complaint
 Symptoms
 Deposits in interior of CRI
 Possible cause
 Poor fuel
No warranty claim.
 Complaint
 Symptoms
 Possible cause
 Poor fuel
No warranty claim.
 Complaint
 Poor starting performance
 Symptoms
 Possible cause
 Water in fuel
 Poor fuel
 Inadequate filtration, poor filter quality or filter
service life exceeded
No warranty claim.
 Complaint
 Symptoms
 Possible cause
 Water in fuel
 Poor fuel
No warranty claim.
 Complaint
 Symptoms
 Possible cause
 Water in fuel
 Poor fuel
No warranty claim.
 Complaint
 Symptoms
 Possible cause
 Water in fuel
 Poor fuel
No warranty claim.
 Complaint
 Symptoms
 Possible cause
 Water in fuel
 Poor fuel
No warranty claim.
 Complaint
 Symptoms
 Possible cause
 Water in fuel
 Poor fuel
No warranty claim.
 Complaint
 Symptoms
 Possible cause
 Water in fuel
 Poor fuel
No warranty claim.
 Complaint
 Symptoms
 Edge type filter corroded
 Nozzle needle corroded
 Possible cause
 Water in fuel
 Poor fuel
No warranty claim.
 Complaint
 Symptoms
 Nozzle needle corroded
 Edge type filter corroded
 Possible cause
 Water in fuel
 Poor fuel
No warranty claim.
 Complaint
Medium  Start problems
 Engine cuts out during journey
 Symptoms
 High-pressure sealing ring worn
 Return quantity too high
 Possible cause
 Old sealing ring design, modification
Severe introduced at beginning of 2004
 Support ring assembly error
 Warranty case
 Complaint
Medium  Start problems
 Symptoms
 High-pressure sealing ring worn
 Possible cause
 Old sealing ring design, modification
Severe introduced at beginning of 2004
 Support ring assembly error
 Warranty case
 Complaint
 Harsh combustion noise (diesel knock)
 Start problems
 Symptoms
 Foreign particles in interior of injector
(blocked inlet hole, cellulose, filter particles)
 Possible cause
 Filter element contaminated with loose
particles
 Incorrect filter installation
No warranty claim.
 Complaint
 Start problems
 Symptoms
 Foreign particles in interior of injector
(packing film in inlet hole)
 Possible cause
 Filter element contaminated with loose
particles
 Incorrect filter installation
 Dirt present when installing injector or lead
No warranty claim.
 Complaint
 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 for new and BX items.
For repaired injector, workshop is
responsible.
 Complaint
 Start problems
 No injection to this cylinder
 Symptoms
 Steel particles in interior of injector
 Possible cause
 Assembly error
 Field repair concept error
Warranty for new and BX items.
For repaired injector, workshop is
responsible.
 Complaint
 Start problems
 Symptoms
 Erosion wear on valve piece ball seat
 Possible cause
No warranty claim.
 Complaint
 Start problems
 Symptoms
 Erosion wear on valve piece ball seat
 Possible cause
No warranty claim.

Defect Catalog

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Defect Catalog

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Copyright:

Verfügbare Formate

CRI / CRIN Defect Catalogue

Product information complete Page 3

Vehicle information complete Page 4

Further test steps:

Test bench audit

Vehicle manufacturer First registration

Vehicle fault code

Chassis number Mileage

Visual inspection for

Visual inspection for

Visual inspection for

Yes Indication of incorrect

Yes Indication of thermal

Test with Bosch test values

Diagnosis of individual parts

Warranty case No Reference to fault

Observe storage periods for spare parts

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