SERVICE BULLETIN - Bosch Australia

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IVECO (EuroCargo-Tector) with Common Rail Diesel Injection System. It is possible to get a customer complaint on hard starting when the engine coolant.
SERVICE BULLETIN Issued by ROBERT BOSCH (AUSTRALIA) PTY. LTD. A.B.N. 48 004 315 628 Incorporated in Victoria

File: Section: Bulletin No: Page: Date: Supersedes:

DISM K - NHA 0009

1 of 3 August 2004

Subject: Starting Problems Associated with 0 445 120 007 Common Rail Injectors (FD 281 – FD 290) when Engine Coolant Temperature above 50°°C Affected Vehicle: IVECO (EuroCargo-Tector) with Common Rail Diesel Injection System It is possible to get a customer complaint on hard starting when the engine coolant temperature is above 50° Celsius. The problem can be associated with an internal leakage of the Common Rail Injector. The high pressure falls below 200 bar (20 Mpa) and the starting time is longer than 3 seconds with a hot engine. Failure Code 0233 – ‘Rail Pressure Monitoring CP3’ (Flash Code 8.1) will be stored in the memory and can be accessed with KTS 5xx/650. The return flow quantity of the injector must be checked at idle speed to confirm the cause. If the return flow quantity is higher than 80 ml /min, the injectors must be replaced. This occurs due to leakage in the solenoid valve area inside the injectors. The return flow passage for all injectors are joined inside the cylinder head; therefore all injectors must be replaced. Method to check the return flow quantity of the injectors: Caution: Be aware of the extremely high pressures associated CRS and exercise due care, attention and cleanliness when working on the system. •

Remove the return flow valve (0.8 bar) together with the return flow pipe (Arrow Fig. 1)



A commercially available fitting is to be connected to the cylinder head with 1 417 413 010 Overflow Valve and a suitable fuel return pipe directed into a container which can also hold a measuring glass (Arrow Fig. 2).



Start and run the engine until it has reached a coolant temperature of 50° C and fuel starts coming out of the return pipe.



Place the pipe into the measuring glass and measure the return flow quantity over a period of one minute.

If the value is under 80 ml/min then the injectors are OK and do not have to be replaced. If the return flow quantity is over 80ml/min, all the injectors are to be replaced. A normal 12 month Bosch Warranty from the date of vehicle registration applies to Injectors with FD 281 to FD 290.

This publication must not be reproduced; its contents must not be transferred to other persons without our written permission, All rights reserved.“ Whilst every care has been taken in the preparation of this publication, Bosch does not warrant the accuracy or completenessof the information inthis publication and Bosch reserves the right to alter specifications without notice. To the extent permitted by law, Bosch excludes all liability, including negligence, for any loss incurred in reliance of the contents of this publication.” SST 1900.1/i-2

SERVICE BULLETIN Issued by ROBERT BOSCH (AUSTRALIA) PTY. LTD. A.B.N. 48 004 315 628 Incorporated in Victoria

File: Section: Bulletin No: Page: Date: Supersedes:

DISM K - NHA 0009

2 of 3 August 2004

Fig.1

Fig. 2

This publication must not be reproduced; its contents must not be transferred to other persons without our written permission, All rights reserved.“ Whilst every care has been taken in the preparation of this publication, Bosch does not warrant the accuracy or completenessof the information inthis publication and Bosch reserves the right to alter specifications without notice. To the extent permitted by law, Bosch excludes all liability, including negligence, for any loss incurred in reliance of the contents of this publication.” SST 1900.1/i-2

SERVICE BULLETIN Issued by ROBERT BOSCH (AUSTRALIA) PTY. LTD. A.B.N. 48 004 315 628 Incorporated in Victoria

File: Section: Bulletin No: Page: Date: Supersedes:

DISM K - NHA 0009

3 of 3 August 2004

Fig. 3

This publication must not be reproduced; its contents must not be transferred to other persons without our written permission, All rights reserved.“ Whilst every care has been taken in the preparation of this publication, Bosch does not warrant the accuracy or completenessof the information inthis publication and Bosch reserves the right to alter specifications without notice. To the extent permitted by law, Bosch excludes all liability, including negligence, for any loss incurred in reliance of the contents of this publication.” SST 1900.1/i-2