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Stepped holder assembly (STH)<br />
Checking and repair<br />
<strong>Service</strong> <strong>Telegram</strong><br />
Robert Bosch GmbH, Automotive Equipment <strong>Service</strong>.<br />
Not to be conveyed to third parties.<br />
Workshop: EP<br />
Following the introduction of concentricity and axial<br />
run-out measurement, both non leak-off and<br />
leakage-return stepped holder assembly repairs<br />
are permissible.<br />
There is no need for conversion of chamfered<br />
shoulder to square shoulder design.<br />
When performing repairs, use can still be made<br />
of service kits available on stock.<br />
Note: This measure does not apply to nozzle-holder<br />
assemblies with needle motion sensor (NBF).<br />
1 = Chamfered shoulder<br />
2 = Square shoulder<br />
1
Nozzle-and-holder assemblies converted to<br />
square shoulder can be identified from retaining<br />
nut with identification groove.<br />
Note:<br />
On nozzle replacement, a new nozzle retaining<br />
nut must always be fitted in chamfered shoulder<br />
seal.<br />
When checking/adjusting opening pressure,<br />
components can be re-used if:<br />
• Spray pattern<br />
• Leakage<br />
• Opening pressure<br />
• and chatter are found to be OK.<br />
1. Special features<br />
Stepped holder assembly repair work is only to<br />
be performed using nozzle tester EPS100 and<br />
an extractor.<br />
Extraction is required to prevent oil mist<br />
escaping into the atmosphere.<br />
Nozzle tester EFEP 60H (0 681 200 502) is no<br />
longer suitable for checking and adjusting all<br />
nozzle-holder assemblies on account of:<br />
* Measurement accuracy<br />
* Dead space<br />
* Pressure gauge quality class<br />
Warranty examinations with EFEP 60H are<br />
not permitted and result in rejection<br />
of warranty claims.<br />
2
2. Tools required:<br />
Nozzle tester EPS 100 0 684 200 704<br />
Extractor EPS 738 (220V) 0 684 200 702<br />
(110V) 0 684 200 703<br />
Test adapter 1 683 391 193<br />
Torque wrench comm. avail.<br />
Micrometer comm. avail.<br />
Nozzle cleaner 0 986 611 140<br />
Test equipment 0 986 612 528<br />
• Concentricity and axial run-out measurement<br />
Pressing-in tool with 0 986 612 473<br />
load cell 0 986 612 459<br />
• Pressing on thermal protection sleeve<br />
or<br />
Load sensor 0 986 612 878<br />
Force transducer 0 986 612 997<br />
• Pressing on thermal protection sleeve<br />
Mounting plate 0 986 611 618<br />
• Pressing down nozzle<br />
Note:<br />
Do not use steel brush to clean nozzle<br />
cone.<br />
This would damage injection orifices.<br />
Commercially available ultrasonic cleaner<br />
Supplier as listed in nozzle test instructions,<br />
"Testers and tools" Section<br />
3
Note on test adapter 1 683 391 193:<br />
Test preparation:<br />
Stepped holder assemblies with no inlet<br />
connector require a connection piece<br />
(test adapter) 1 683 391 193.<br />
Test adapter consists of holder and thrust piece.<br />
Stepped holder assembly is inserted in holder and<br />
fixed in position and sealed with thrust piece.<br />
The existing injection tubing is connected<br />
to this thrust piece.<br />
The thrust piece contains a built-in edge-type<br />
filter to protect the nozzle-and-holder assembly.<br />
3 = Test adapter<br />
4
Checking and adjusting stepped holder assembly<br />
Test preparation:<br />
Holder is prepared for different diameters and<br />
connection angles.<br />
Clean stepped holder assembly prior to fitting in<br />
holder.<br />
Insert stepped holder assembly in holder.<br />
In line with angle of inlet passage at nozzleholder<br />
assembly, screw thrust piece into appropriate<br />
tapped hole 1, 2 or 3 in holder and secure.<br />
1 = Angle 0°<br />
2 = Angle 20.0°<br />
3 = Angle 13.5°<br />
5
Note: Checking non leak-off stepped holder assembly<br />
Pay attention to the following when checking<br />
non leak-off stepped holder assembly:<br />
Once hand lever of nozzle tester EPS100 has<br />
been actuated approx. three times, spring chamber<br />
above nozzle needle in holder is full of calibrating oil.<br />
Hand lever can no longer be actuated (movement<br />
of nozzle needle against hydraulic cushion) by hand.<br />
Before further tests still required can be performed,<br />
nozzle retaining nut must be carefully unfastened to<br />
dissipate pressure from spring chamber.<br />
After unfastening, nozzle retaining nut is always to<br />
be tightened again to specified torque of 40...50 Nm.<br />
Note:<br />
Tightening torque for Mack / RVI stepped holder<br />
assembly is 60...70 Nm.<br />
6
Check stepped holder assembly for:<br />
• Opening pressure<br />
• Spray pattern<br />
• Leakage<br />
• and chatter<br />
Check opening pressure as per adjustment table.<br />
If opening pressure is not within tolerance, dismantle<br />
stepped holder assembly and adjust opening pressure.<br />
Dismantling stepped holder assembly:<br />
Remove thermal protection disk or packing<br />
plate if fitted.<br />
Unfasten and unscrew nozzle retaining nut.<br />
Remove nozzle, adapter plate and pressure pin.<br />
Remove compression spring and shim from holder.<br />
Use micrometer to measure thickness of shim removed.<br />
1 = Shim<br />
7
Select corresponding shim from parts list.<br />
Note:<br />
0.01 mm = 2 ... 4 bar.<br />
Ensure cleanliness when fittting nozzle-holder<br />
assembly.<br />
If necessary, fit new nozzle with new nozzle retaining nut<br />
(chamfered shoulder seal).<br />
Insert shim, compression spring, adapter plate<br />
and pressure pin in holder.<br />
Make sure fitted pins (straight pins) of adapter<br />
plate are correctly positioned in holder and nozzle.<br />
Note:<br />
Tapered end of pressure pin faces adapter plate.<br />
Fit nozzle in position and screw nozzle retaining nut<br />
slightly onto holder.<br />
Before retaining nut makes contact with nozzle, insert<br />
entire nozzle-and-holder assembly in appropriate<br />
recess of mounting plate.<br />
Insert appropriate thrust piece in press tool holder<br />
of hand press.<br />
8
With nozzle pressed down, tighten nozzle<br />
retaining nut to specified torque.<br />
Nozzle-and-holder assembly:<br />
Type KBAL..P 30...40 Nm<br />
Type KBEL..P 40...50 Nm<br />
Note:<br />
Tightening torque for Mack / RVI stepped holder<br />
assembly is 60…70 Nm.<br />
Measure/check<br />
• Leakage<br />
• Spray pattern<br />
• Opening pressure<br />
• and chatter.<br />
Adjustment procedure has been completed if opening<br />
pressure is within tolerance.<br />
10
Note:<br />
Always measure concentricity and axial run-out<br />
after unfastening nozzle retaining nut.<br />
Procedure:<br />
Insert stepped holder assembly in measuring<br />
device 0 986 612 528 and secure.<br />
Insert dial gauge for concentricity measurement<br />
in mount and secure.<br />
If available, fit 2nd dial gauge for axial<br />
run-out measurement.<br />
Turn support ring with nozzle-holder<br />
assembly.<br />
Measure nozzle concentricity with dial gauge 2.<br />
Max. eccentricity 0.4 mm<br />
Measure axial run-out at end face of nozzle<br />
retaining nut.<br />
Max. axial run-out 0.08 mm<br />
1 = Dial gauge for axial run-out measurement<br />
2 = Dial gauge for concentricity measurement<br />
3 = Nozzle holder assembly mount<br />
11
Additional operations for stepped holder assembly<br />
with thermal protection sleeve<br />
Use is made as combustion chamber seal of a<br />
thermal protection sleeve or Cu packing plate.<br />
Thermal protection sleeve or Cu packing plate must<br />
always be replaced on installation after dismantling<br />
stepped holder assembly.<br />
Nozzle stem must not be subject to lateral<br />
forces when installed.<br />
Press in thermal protection sleeve in specified manner<br />
(do not use vice).<br />
Effects of lateral forces:<br />
- Sticking of nozzle needle<br />
- Danger of collar of thermal protection sleeve<br />
being damaged – if collar is fractured, cylindrical<br />
section of thermal protection sleeve slides<br />
downwards and alters injection jet.<br />
• Complaint : Black smoke<br />
No power<br />
1 = Thermal protection sleeve must not come into<br />
contact with hole<br />
12
When pressing on thermal protection sleeve, make sure<br />
direction of pressing-in force is absolutely vertical.<br />
Use pressing-in tool 0 986 612 473 with load<br />
cell 0 986 612 459 for pressing on thermal<br />
protection disk.<br />
Alternatively, use can also be made of load sensor<br />
0 986 612 878 with force transducer 0 986 612 997.<br />
Note:<br />
Two M6 holes are provided on lower plate for<br />
use of load sensor.<br />
Use can be made of components of pressing-in tool<br />
... 473 with the exception of the base plate.<br />
Fig. shows load sensor 0 986 612 878<br />
13
Use of pressing-in tool:<br />
Position stepped holder assembly in nozzle<br />
holder assembly mount with pressure end<br />
facing downwards.<br />
Attach thermal protection sleeve to stem of nozzle<br />
to suit version.<br />
Thermal protection sleeves:<br />
Bush length 19.4 mm<br />
Bush length 17.3 mm<br />
Position corresponding thrust piece on thermal<br />
protection sleeve.<br />
1 = Thrust piece (19.4 and 17.3 mm version)<br />
2 = Thermal protection sleeve<br />
3 = Nozzle-holder assembly<br />
4 = Nozzle-holder assembly mount<br />
5 = Load cell<br />
14
Insert dial gauge in mounting hole provided and<br />
secure.<br />
Press thermal protection sleeve onto nozzle<br />
whilst constantly observing load cell reading.<br />
Set dial gauge to "0" as soon as pressing-in<br />
force of 200 Nm is attained.<br />
Continue pressing in thermal protection sleeve<br />
whilst constantly observing pressing-in force.<br />
Force must not exceed 850 Nm whilst<br />
pressing in.<br />
As of a distance of 1 mm from start of travel<br />
measurement, pressing-in force must not drop below<br />
200 Nm until pressing-in is completed.<br />
Continue pressing and determine force at reversal<br />
point. Keep pressing until pressing-in force is<br />
equal to force previously determined at reversal<br />
point + 200...230 Nm.<br />
In doing so, pressing-in force must not exceed<br />
850 Nm.<br />
The total pressing-in distance must be 3.0 mm.<br />
On completion of pressing-in process, it must not be<br />
possible to detach thermal protection sleeve by hand.<br />
Check whether entire periphery of thermal protection<br />
sleeve collar is in contact with nozzle retaining nut, as<br />
otherwise thermal protection sleeve will not function<br />
properly.<br />
Attention:<br />
Nozzle cone must not exhibit any signs of damage.<br />
15
4. Opening pressure table<br />
Stepped holder<br />
assembly<br />
Opening<br />
pressure bar<br />
Type number<br />
of holder<br />
Nozzle<br />
0432191296 320...328 - -<br />
0432191301 245...259 - -<br />
0432191302 245...259 - -<br />
0432191303 245...259 - -<br />
0432191304 245...259 - -<br />
0432191305 245...259 - -<br />
0432191306 245...259 - -<br />
0432191307 245...259 - -<br />
0432191308 245...259 - -<br />
0432191310 320...328 - -<br />
0432191311 320...330 KBEL 100 P26 0 433 171 725<br />
0432191315 300...310 KBEL 106 P228 0 433 171 809<br />
0432191316 290...302 KBEL 100 P141 0 433 171 807<br />
0432191317 290...302 KBEL 100 P141 0 433 171 806<br />
0432191319 300...314 KBEL 137 P174 0 433 171 802<br />
0432191320 300...314 KBEL 137 P174 0 433 171 803<br />
0432191321 245...259 KBEL 100 P169 0 433 171 797<br />
0432191323 250...262 KBEL 99 P188 0 433 171 784<br />
0432191329 320...328 KBEL 94 P218 0 433 171 764<br />
0432191331 320...330 KBEL 100P240 0 433 171 761<br />
0432191332 320...330 KBEL 100P240 0 433 171 760<br />
0432191333 320...330 KBEL 100P240 0 433 171 759<br />
0432191334 320...330 KBEL 100P240 0 433 171 758<br />
0432191344 245...259 KBEL 100P169 0 433 171 746<br />
0432191347 290...302 KBEL 100P236 0 433 171 741<br />
0432191348 290...302 KBEL 100P236 0 433 171 740<br />
0432191349 300...314 KBEL 84 P162 0 433 171 742<br />
0432191355 300...314 KBEL 84 P162 0 433 171 735<br />
0432191357 300...314 KBEL 93 P216 0 433 171 728<br />
0432191359 325...337 KBEL 100P141 0 433 171 634<br />
0432191360 325...337 KBEL 100P141 0 433 171 450<br />
0432191362 320...330 KBEL 100P141 0 433 171 725<br />
0432191363 290...302 KBEL 100P141 0 433 171 724<br />
0432191370 290...302 KBEL100P141 0 433 171 607<br />
0432191372 290...302 KBEL 100P141 0 433 171 610<br />
0432191381 300...310 KBEL 106P228 0 433 171 703<br />
0432191382 300...310 KBEL 106P228 0 433 171 702<br />
0432191384 290...302 KBEL 100P141 0 433 171 628<br />
0432191385 290...302 KBEL 100P141 0 433 171 696<br />
0432191387 290...300 KBEL 100P141 0 433 171 691<br />
0432191389 300...314 KBEL 93 P216 0 433 171 687<br />
0432191390 300...314 KBEL 93 P216 0 433 171 686<br />
0432191391 300...314 KBEL 93 P216 0 433 171 685<br />
0432191392 300...314 KBEL 93 P216 0 433 171 684<br />
0432191393 245...259 KBEL 100P169 0 433 171 680<br />
0432191394 245...259 KBEL 100P169 0 433 171 680<br />
0432191395 245...259 KBEL 100P169 0 433 171 679<br />
0432191396 245...259 KBEL 100P169 0 433 171 679<br />
0432191400 290...302 KBEL 100P141 0 433 171 676<br />
0432191407 280...292 KBEL 100P141 0 433 171 436<br />
16
0432191410 300...314 KBEL 162P209 0 433 171 658<br />
0432191416 320...328 KBEL 94 P218 0 433 171 583<br />
0432191419 300...308 KBEL 94 P218 0 433 171 640<br />
0432191421 320...328 KBEL 94 P218 0 433 171 639<br />
0432191422 300...314 KBEL 93 P216 0 433 171 656<br />
0432191423 320...330 KBEL 100P141 0 433 171 655<br />
0432191424 250...262 KBEL 99 P188 0 433 171 653<br />
0432191426 300...314 KBEL 93 P216 0 433 171 651<br />
0432191427 320...330 KBEL 100P141 0 433 171 643<br />
0432191434 245...259 KBEL 100P184 0 433 171 637<br />
0432191437 325...337 KBEL 100P967 0 433 171 634<br />
0432191446 290...302 KBEL 100P141 0 433 171 628<br />
0432191453 290...302 KBEL 100P141 0 433 171 620<br />
0432191454 300...314 KBEL 93 P177 0 433 171 615<br />
0432191456 290...302 KBEL 100P141 0 433 171 610<br />
0432191459 290...302 KBEL 100P141 0 433 171 607<br />
0432191462 245...259 KBEL 100P184 0 433 171 578<br />
0432191463 245...259 KBEL 100P169 0 433 171 566<br />
0432191467 320...330 KBEL 100P141 0 433 171 599<br />
0432191468 245...259 KBEL 100P184 0 433 171 597<br />
0432191469 320...330 KBEL 100P141 0 433 171 595<br />
0432191470 300...310 KBEL 106P135 0 433 171 593<br />
0432191484 300...314 KBEL 84 P162 0 433 171 514<br />
0432191488 245...259 KBEL 100P169 0 433 171 566<br />
0432191489 245...259 KBEL 100P169 0 433 171 688<br />
0432191491 250...262 KBEL 99 P188 0 433 171 612<br />
0432191498 300...314 KBEL 93 P177 0 433 171 525<br />
0432191501 245...259 KBEL 100P184 0 433 171 561<br />
0432191503 320...330 KBEL 100P141 0 433 171 559<br />
0432191504 300...310 KBEL 106P135 0 433 171 557<br />
0432191514 320...330 KBEL 100P141 0 433 171 548<br />
0432191526 245...259 KBEL 100P169 0 433 171 688<br />
0432191534 300...314 KBEL 162 P164 0 433 171 534<br />
0432191543 320...330 KBEL 100P141 0 433 171 527<br />
0432191551 325...337 KBEL 100P141 0 433 171 436<br />
0432191553 320...330 KBEL 100P141 0 433 171 520<br />
0432191560 290...304 KBAL 137 P26 0 433 171 507<br />
0432191570 230...238 KBEL 106P135 0 433 171 493<br />
0432191583 230...240 KBEL 106P135 0 433 171 465<br />
0432191584 300...310 KBEL 100 P127 0 433 171 476<br />
0432191589 325...337 KBEL 100P141 0 433 171 450<br />
0432191604 230...238 KBEL 106P135 0 433 171 438<br />
0432191596 300...310 KBEL 100 P127 0 433 171 450<br />
0432191620 320...330 KBEL 100 P127 0 433 171 436<br />
0432191649 300...314 KBAL 137 P26 0 433 171 341<br />
0432191750 250...264 KBEL 84 P 93 0 433 171 340<br />
0432191757 250...264 KBAL 137 P26 0 433 171 173<br />
0432191762 270...284 KBAL 137 P14 0 433 171 158<br />
0432191767 250...264 KBAL 137 P14 0 433 175 010<br />
0432191769 250...264 KBAL 137 P14 0 433 171 158<br />
0432191786 295...309 KBAL 137 P14 0 433 171 138<br />
0432193490 245...259 - -<br />
0432193491 245...259 - -<br />
0432193492 240...260 - -<br />
0432193493 240...260 - -<br />
0432193500 245...259 KDEL 100P169 0 433 175 350<br />
17
0432193502 240...260 KBEL 187P230 0 433 175 383<br />
0432193503 240...260 KBEL 137P230 0 433 175 384<br />
0432193504 240...260 KBEL 137P230 0 433 175 385<br />
0432193505 240...260 KBEL 137P230 0 433 175 374<br />
0432193506 240...260 KBEL 137P230 0 433 175 316<br />
0432193507 240...260 KBEL 137P230 0 433 175 375<br />
0432193515 240...260 KBEL 137P230 0 433 175 359<br />
0432193516 240...260 KBEL 137P230 0 433 175 358<br />
0432193518 250...262 KBEL 137P232 0 433 175 355<br />
0432193521 245...259 KBEL 100P169 0 433 175 350<br />
0432193522 245...259 KBEL 100P169 0 433 175 349<br />
0432193528 300...314 KBEL 137P174 0 433 175 329<br />
0432193529 300...314 KBEL 137P174 0 433 175 330<br />
0432193530 300...314 KBEL 137P174 0 433 175 331<br />
0432193531 300...314 KBEL 137P174 0 433 175 332<br />
0432193534 240...260 KBEL 137P230 0 433 175 321<br />
0432193539 200...220 KBEL 137P230 0 433 175 316<br />
0432193540 200...220 KBEL 137P230 0 433 175 315<br />
0432193567 300...314 KBEL 137P161 0 433 175 165<br />
0432193568 300...314 KBEL 137P161 0 433 175 167<br />
0432193581 300...314 KBEL 84 P162 0 433 175 249<br />
0432193629 300...314 KBEL 84 P162 0 433 175 215<br />
0432193630 300...314 KBEL 84 P162 0 433 175 212<br />
0432193635 300...314 KBEL 84 P162 0 433 175 210<br />
0432193645 300...314 KBEL 84 P178 0 433 175 202<br />
0432193646 300...314 KBEL 84 P178 0 433 175 201<br />
0432193647 300...314 KBEL 84 P178 0 433 175 200<br />
0432193648 300...314 KBEL 84 P178 0 433 175 198<br />
0432193649 300...314 KBEL 84 P178 0 433 175 197<br />
0432193652 300...314 KBEL 84 P178 0 433 175 180<br />
0432193653 300...314 KBEL 84 P178 0 433 175 170<br />
0432193659 300...314 KBEL 84 P162 0 433 175 182<br />
0432193671 300...314 KBEL 137P174 0 433 175 165<br />
0432193672 300...314 KBEL 137P174 0 433 175 167<br />
0432193673 300...314 KBEL 137P174 0 433 175 166<br />
0432193674 300...314 KBEL 137P174 0 433 175 162<br />
0432193770 260...274 KBAL 137 P26 0 433 175 102<br />
0432193796 260...274 KBAL 137 P26 0 433 175 096<br />
0432193803 260...274 KBAL 137 P26 0 433 175 090<br />
0432193804 260...274 KBAL 137 P26 0 433 175 089<br />
0432193805 260...274 KBAL 137 P26 0 433 175 088<br />
0432193831 260...274 KBAL 137 P28 0 433 175 064<br />
0432193832 260...274 KBAL 137 P 28 0 433 175 063<br />
0432193833 260...274 KBAL 137 P28 0 433 175 062<br />
0432193862 260...274 KBAL 137 P26 0 433 175 037<br />
0432193863 260...274 KBAL 137 P26 0 433 175 036<br />
0432193864 260...274 KBAL 137 P26 0 433 175 035<br />
0432193868 260...274 KBAL 137 P28 0 433 175 026<br />
0432193873 260...274 KBAL 137 P26 0 433 175 020<br />
0432231007 190...198 KDAL 50S4/4 0 433 220 078<br />
0432231014 175...183 KDAL 82S15/4 0 433 220 129<br />
0432231029 195...203 KDAL 50S4/4 0 433 220 157<br />
0432231041 220...228 KDAL 126S17/4 0 433 220 185<br />
0432231043 220...228 KDAL 126S17/4 0 433 220 184<br />
0432231044 175...183 KDAL 96 S16/4 0 433 220 187<br />
0432231045 230...238 KDAL 126S17/4 0 433 220 177<br />
18
0432231053 220...228 KDAL 126S17/4 0 433 220 199<br />
0432231698 280...288 KDAL 62S38 0 433 271 715<br />
0432291524 325...333 KDALZ 83S85 0 433 271 631<br />
0432291624 210...218 KBAL 73S41/13 0 433 271 736<br />
0432291637 240...248 KBALZ 153S53 0 433 271 492<br />
0432291642 210...218 KBAL 73S41/13 0 433 271 763<br />
0432291643 190...198 KBAL 62S29/13 0 433 271 763<br />
0432291681 240...248 KBALZ 153 S53 0 433 271 464<br />
0432291683 240...248 KBALZ 153 S53 0 433 271 460<br />
0432291711 190...198 KBALB 87S3 0 433 271 828<br />
0432291802 215...223 KBAL 154 SB1/13 0 433 271 332<br />
0432291806 250...258 KBALC 118S6/4 0 433 271 323<br />
0432291813 250...258 KBALC 118S6/4 0 433 271 316<br />
0432291827 235...243 KBAL 154SB1/13 0 433 271 291<br />
0432291847 190...198 KBAL 62S29/13 0 433 271 261<br />
0432292860 300...314 KBEL 162S93 0 433 272 980<br />
0432292861 300...314 KBEL 162 S93 0 433 272 985<br />
0432292863 300...314 KBEL 162 S93 0 433 271 603<br />
19
Heed the following on attaching inlet connector:<br />
There must not be any visible blemishes or signs of<br />
deformation at conical surface forming seal with tubing.<br />
Spherical sealing surface of inlet connector must not<br />
exhibit any signs of wear.<br />
Note:<br />
Always replace and lubricate O-rings.<br />
Recommendation:<br />
Always replace inlet connector following disassembly.<br />
Check crucial locations on holder:<br />
Visually inspect:<br />
• Sealing cone hydraulic connection<br />
• O-ring seals<br />
20
Notes on fitting stepped holder assembly<br />
For centering high-pressure connection of stepped<br />
holder assembly with respect to inlet connector,<br />
insert but do not tighten stepped holder assembly.<br />
Stepped holder assembly installation procedure:<br />
1. Insert stepped holder assembly in cylinder head bore<br />
(before fitting, replace and lubricate O-rings at stepped<br />
holder assembly).<br />
2. Fit retainer and screw in corresponding M8<br />
bolt by hand.<br />
3. Apply grease to O-ring at inlet connector and<br />
fit O-ring.<br />
When fitting, make sure ball (if applicable)<br />
of inlet connector is positioned in cylinder<br />
head groove<br />
(loose stepped holder assembly is automatically<br />
centered with inlet connector).<br />
4. Tighten retainer with corresponding M8 bolt<br />
to 30 +3 Nm.<br />
5. Tighten union nut at inlet connector to<br />
40 + 5 Nm.<br />
When securing, make sure inlet connector does<br />
not become deformed (bent).<br />
1 = Injection tubing<br />
3 = Clamping screw<br />
4, 7 = O-ring<br />
5 = Inlet connector<br />
8 = M8 bolt<br />
9 = Retainer<br />
10 = Thermal protection sleeve<br />
21
6. Tighten union nut of injection tubing to<br />
25 + 2 Nm.<br />
Connect injection tubing to inlet connector,<br />
taking care to avoid strain as far as possible.<br />
High-pressure connection test method<br />
7. High-pressure connection vacuum test at<br />
inlet connector (possibly using Mityvac pump).<br />
Replace inlet connector if vacuum cannot be<br />
built up.<br />
Check sealing surface at high-pressure<br />
connection of stepped holder assembly.<br />
Inlet connector<br />
Retaining screw<br />
Optionally lubricated and/or with<br />
anti-friction coating at<br />
- O-ring<br />
- Exposed annular area<br />
- Thread<br />
22
Fitting and removing Cu packing plate<br />
When fitting and removing, take care not to damage<br />
nozzle cone.<br />
Damage in the area of the injection orifices would<br />
alter the spray pattern.<br />
If seized, grasp hold of packing plates with pliers<br />
and detach by twisting slightly.<br />
Use is made as combustion chamber seal of a<br />
Cu packing plate.<br />
After dismantling stepped holder assembly, Cu<br />
packing plate must always be replaced on installation.<br />
Nozzle stem must not be subject to lateral<br />
forces when installed.<br />
Cu packing plate must be free to deform in radial<br />
direction under the influence of axial force and must<br />
not make radial contact with bore in cylinder head.<br />
The centering lugs ensure free deformation of Cu<br />
packing plate towards nozzle without lateral forces<br />
acting on nozzle stem.<br />
1 = Cu packing plate must not make contact with hole.<br />
2 = Nozzle stem must not make contact with bore in<br />
cylinder head.<br />
3 = Centering lugs prevent one-sided contact of<br />
Cu packing plate with nozzle stem<br />
(no asymmetrical forces on nozzle stem).<br />
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Published by:<br />
Robert Bosch GmbH<br />
Automotive Aftermarket<br />
Diesel Systems Product Marketing<br />
(AA/PDS1)<br />
Please address enquiries to local<br />
BOSCH representative.<br />
24
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