Department | 11.07.2006 | © All rights, including patent applications, reserved by Robert Bosch GmbH.

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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 Indication of incomplete vehicle information In warranty period CRI/CRIN Product information complete 1 Vehicle information complete No Yes Reject product information Indication of expired warranty period Bosch product Indication of third-party product Page 3 4 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 1 Further test steps: Visual check Test bench audit Dismantling Test bench audit Further test steps: 1 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 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 number Engine number First registration Date of sale Vehicle fault code (if available) Vehicle manufacturer Engine manufacturer Vehicle model Mileage 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 Yes No 2 Visual inspection for mechanical damage Indication of mechanical damage Visual inspection for mechanical damage outside intervention Rejection Yes No Indication of outside intervention 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.

Visual Inspection 2 Yes No Ultrasonic cleaning of injector Visual inspection for mechanically cleaned, brushed injectors Indication of incorrect service center procedure Yes No Rejection thermal overload of injector Indication of thermal Overload, check engine for consequential damage Ultrasonic cleaning of injector 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 Bench Audit Ultrasonic cleaning of injector No Yes Test with Bosch test values on Bosch EPS 815 test bench Ultrasonic cleaning of injector Dismantling No Yes Injector OK No warranty case 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 Ultrasonic cleaning of individual part No Yes Diagnosis of individual parts Evaluation against fault symptoms catalogue Acknowledge warranty Observe storage periods for spare parts Dismantle injector in line with ESI instructions Ultrasonic cleaning of individual part No Yes Warranty case Rejection Reference to fault 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.

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

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

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

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 angle Warranty decision: No warranty claim. No material or manufacturing fault Automotive Aftermarket Abteilung | 18.09.2006 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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 Supplement repair instructions with vehicle specific information Automotive Aftermarket Abteilung | 18.09.2006 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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

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 Note in warranty inspection description: The engine must be investigated for possible damage during continuous injection, stethoscope on piston head. Automotive Aftermarket Abteilung | 18.09.2006 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Common Rail Injector (Passenger Car + Commercial Vehicle) 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 Automotive Aftermarket Abteilung | 18.09.2006 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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

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

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

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

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

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

Common Rail Injector (Passenger Car + Commercial Vehicle) 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 Automotive Aftermarket Abteilung | 18.09.2006 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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

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

Common Rail Injector (Passenger Car + Commercial Vehicle) 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 Automotive Aftermarket Abteilung | 18.09.2006 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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