Bosch Common Rail

Fuel Injection System

Version 2.0*

*Updated as on December 2019.

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Contents

1 Bosch Common Rail System 4

2 Generations of CRS 5

3 Bosch Common Rail Injectors 6

▶ Common Rail Injectors - Passenger Cars 8

▶ Common Rail Injectors - Commecial Vehicles 9

▶ Piezo Injector 10

4 High Pressure Pumps 11

5 Distributor Tube / Rail / Accumulator 16

6 DNox 17

7 Bosch Common Rail Systems Application Chart 18

8 Bosch CR Systems Spare Parts List

▶ CR Pumps 67

▶ CRI Injectors 71

▶ CRIN Injectors 73

▶ Rail 74

▶ CRI Repair Kit 76

▶ CRIN Repair Kit 76

▶ CR Shim Kit 77

9 Special Case Explanation 87

Product HSN Code Tax %

CR Pumps 84133010 28
CR Pump Spares 84139190 18
Rail / Distributor Tubes 84099941 28
Rail Spares 84811019 18
CR Injectors 84099930 28
CR Injector Spares 84099990 28
 Bosch Common Rail System
The Bosch fuel injection system delivers the metered quantity at high pressure to mix with compressed air inside the combustion
chamber for efficient combustion. The Bosch Common Rail Fuel Injection System (Bosch CRS) is an innovative, efficient, and
economical high-pressure injection technology that makes today’s vehicles more attractive than ever before.

Bosch CRS features:

 Reliable technology for high-performance diesel engines
 Genuine OE components
 Modular design for ease of servicing

Generations of Bosch CRS

Cr Generation Max. Prsr. Injector High Pressure Pump
(Bar) Type
1st Generation 1,350– Solenoid- CP1
Passenger Cars 1,450 Valve Pressure control on
Injector high-pressure side
(Rail) by pressure-
control valve
1st Generation 1,400– Solenoid- CBx
Commercial 1,800 Valve Pressure control on
Vehicles Injector suction side (Pump)
fuel delivery control
The Bosch Common Rail System consists of a high-pressure pump, rail, and injector. by two solenoid
valves
2nd Generation 1,600 Solenoid- CP3, CP1H
Passenger Cars Valve Suction-side fuel
& Commercial Injector delivery control
Vehicles by metering unit
3rd Generation 1,600– Piezo- CP3, CP1H, CP4.1
Passenger Cars 1,800 Inline Suction-side fuel
Injector delivery control by
metering unit
3rd Generation 1,800 Solenoid- CP3.3NH, CP4.2
Commercial Valve Metering unit
Vehicles Injector

You can rely on the world’s leading diesel system

supplier for passenger cars, off-highway,
and commercial vehicles.

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 When it is time to
replace the injector,
Bosch is the only choice.

Bosch Common Rail Injectors

Benefits to the customer:
The Bosch Common Rail Injector injects the precise amount of fuel into the combustion chamber
at the right time and in the right quantity. This can be actuated with a solenoid on the injector,  Optimum torque
Human hair
and the duration and timing will be controlled by the ECU (Electronic Control Unit). (dia. 0.06 mm)
 Lower emmission and noise
Pressure
2,050 bar
levels
 Lower fuel consumption
Features:
Clearance 0.002 mm

 World’s most sophisticated common rail  Superior and comfortable

 Operates up to 2,050 bar pressure of Pinhead (2 mm3)
diesel injector design driving experience
injection which is equal to the weight of a
sedan on the nail of a human.  Designed and engineered with every
 Multiple injections of up to 8/stroke component representing a unique
technology
 Maintains the quality and performance 0.33 m/ms
Speed of sound
 Has undergone hydro-erosion machining Injected fuel quantity
1–350 mm3
process for intricate hole size that is equal Injection duration
to one-third the human hair diameter 1–2 ms

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 Common Rail Injectors for Common Rail Injectors for
Passenger Cars and their Commercial Vehicles and their
specifications specifications

CRI 1 - 14 CRI 2 - 16 CRIN 1-14-16 CRIN 2-16

Injection pressure 1,400 bar Injection pressure 1,600 bar Injection pressure 1,400–1,600 bar Injection pressure 1,600 bar
Type of actuation Solenoid control Type of actuation Solenoid control Type of actuation Solenoid control Type of actuation Solenoid control
Multiple injections Yes Multiple injections Yes Multiple injections Yes Multiple injections Yes
Application PC, LCV Application PC, LCV, & OHW Application LCV, HCV Application LCV, HCV

CRI 3 - 16-18-20 CRIN 3-18

Injection pressure 1,600–2,000 bar Injection pressure 1,800 bar
Type of actuation Piezo control Type of actuation Solenoid control
Multiple injections Yes Multiple injections Yes
Application PC, LCV Application LCV, HCV

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 High Pressure Pump
(Common Rail Pump)
Bosch common rail high-pressure pump continuously generates
high-pressure fuel and supplies it to the rail.
Features:
 Injection pressures ranging from 1,400 to 2,800 bar can be
achieved with different generations of Bosch CRS
 Bosch has multiple variants of high-pressure pumps for passenger
cars, light-duty vehicles, and heavy-duty vehicles separately
 Robust and compact design

Advantages:
 Increased service life with Bosch technology reduces the service
cost to customer
 Bosch genuine service parts increase the pump service life and
efficiency of the engine

Types of Bosch High Pressure Pumps

Diesel technology trend changer
Piezo Injector CP3x
The latest technology in Bosch injectors is the Piezo Injector. It is actuated by
piezo material which converts electrical energy to mechanical energy. CP1x

Benefits:
 Extremely short injection intervals possible
 No continuous back leak of fuel, which
reduces energy consumption
 Very high needle opening and closing, leading
to improved engine performance
 Robust design with module concept

CBx

CP4x

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 CP1x CBx
(Radial Piston Pumps) (Banked Piston Pumps)
CP1x is the first generation of Bosch common CBx pumps are high-pressure, second-generation systems are required to meet the new emission
rail pump with 3-plunger radial piston and can common rail pumps for on- and off-highway norms like BS IV and BS VI.
generate up to 1,400 bar fuel pressure. vehicles. Specifically created for emerging
With this technology from Bosch, existing
markets where stringent future regulation of
engines which were designed for in-line pumps
emissions is expected, and where change from
can be replaced with CBx pumps with minor
mechanical to electronically controlled injection
modification in the engine.

CBx variants and their specifications

CP1x variants and their specifications: Technical specifications CB18 CB28

Pump type 2 piston in-line 2 piston in-line
Technical specifications CP1K CP1H CP1S
System pressure (bar) 1,800 1,800
Number of cylinders 3 3 3
Cam lobes 2 or 3 2 or 3
System pressure (bar) 1,300 1,400 1,400
Supply pump Vane type Vane type
Pressure controlled by DRV on rail Metering unit Metering unit
Lubrication Oil Oil
Element switch-off valve No No Yes
Applications LCV, HCV LCV, HCV
Drive coupling Oldham Gear Gear
Applications PC, LCV PC, LCV PC, LCV

Benefits:
Benefits:  Easy to integrate into existing engine concepts

 Compact and lightweight system design by Oldham coupling  Integrated mechanical supply pump assures constant fuel availability for delivery

 Low fuel consumption with subsequent reduction of CO2 output  In one rotation three injections from the pump are achieved through three cam lobes on the shaft

 Pressure control on the low pressure side reduces the load on the pump and heating of fuel
 In a downhill condition, the element switch-off valve stops the function of the element partially and
load on the pump will reduce, leading to lower fuel consumption

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 CP3 CP4x
Bosch High Pressure Pumps Bosch High Pressure Pumps
CP3 is the first high-pressure pump with pressure CP4x pumps can generate pressure in the
control on the lower pressure side done by the range of 1,600–2,200 bar to atomize the fuel
metering unit. It is a 3-plunger radial piston pump and combust properly to achieve higher engine
with a monoblock housing. performance.

CP3 specifications CP4x variants and their specifications

Technical Specifications Technical specifications CP4.1 CP4.2

No. of pump cylinders 3 No. of pump cylinders 1 2
Pressure (bar) 1,600 Pressure (bar) 1,600 1,800–2,000
Cam lobes 3 Cam lobes 2 2
Lubrication Oil Lubrication Fuel Fuel
Fuel control Fuel control by metering unit Fuel control Fuel control by metering unit Fuel control by metering unit
Supply pump Gear pump Supply pump EKP Gear pump
Applications LCV, HCV Applications PC, LCV, HCV PC, LCV, HCV

Benefits: Benefits:
 Compact monoblock design  Compact and lightweight
 Suction-based fuel delivery control by metering unit, which compresses the fuel as needed  It is intended for light-duty vehicles at optimum price
 This reduces the load on the pump and decreases the fuel heating  It
delivers fuel to the rail on a specified crank angle to eliminate the pressure pulsation in the rail
while injecting the fuel into combustion chamber
 Pressure
control at suction achieves lower fuel consumption and the same technology is used in
CP1H pump later  In one revolution of the pump shaft, the piston delivers two pumping events

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