Injector Extraction Kit for the M9R / M9T

Transcription

1 Work Instructions Injector Extraction Kit for the M9R / M9T Tensile Force Limiter page 1 of 40

2 page 2 of 40

3 Safety notice Important! Be sure to read these instructions before assembling, during installation and throughout use. The application of the tools should only be carried out by qualified personnel. Always refer to the OEM manufacturer s instructions and service manuals for the latest data and to maintain the correct sequence. These work instructions and the recommended tools shown are meant to serve as aides only and are by no means a guarantee for certain results. In some cases, due to insufficient space the engine or the cylinder head will need to be removed. This tool kit is a special collection and it has been tested and used successfully on several occasions. It is of the utmost importance to maintain the correct sequence as per the instructions. Pictograms and their meaning: Special caution or attention Hint or recommendation Wear safety goggles Right Wrong page 3 of 40

4 M9R Injector Extraction Kit N P/n Description * Hydraulic Cylinder 12 t Pin Wrench Tap M18x Tool Holder with Guide for Tap M18x Extraction Spindle M18x1.5 Stepped to M16x Tap M16x Tool Holder with Guide for Tap M16x Extraction Spindle M16x1.5x Support Bridge Leg Support Bridge Adapter M16x Straddling Dowel (packing unit: 4 pcs) Pull Rod for Straddling Dowel Box Nut Adaptor Sealing Plugs with Setting Tool 10mm Allen Socket 10 with Hole (Custom made) Extraction Adapter for Solenoid Controlled Injectors Box Nut Adaptor for Solenoid Controlled Injectors Sleeve Adaptor for Solenoid Controlled Injectors Adapter M18x Stud Remover Twist Socket 1/2" Drive Extraction Adapter for Piëzo Controlled Injectors Open Screw Extraction Adapter M16x2 to M16x Pipe Brush Extraction Spindle M16x2x95mm * Supplementary kit to with foam insert. page 4 of 40

5 M9R Injector Extraction Supplementary Kit N P/n Description Flexible Bit Holder 1/4 " Tap M20x1, Tap Holder Brush Holder Extraction Spindle Stepped M20x1,5 / M Hole Saw Arbour Tube Brush Ø26mm Hole Saw Hole Saw Guide 1 1 M9R Injector Extraction Supplementary Tensile Force Limiter N P/n Description Tensile Force Limiter Top Section Shear Pin 6h8 x35mm O-Ring NNR70 32x Tensile Force Limiter Bottom Section 1 page 5 of 40

6 Contents: What s the problem? 6-7 Page 1: Piëzo controlled injector is stuck 8-13 Preparation Extraction with the Tensile Force Limiter Extraction with the Double Attachment 2: Solenoid controlled injector is stuck Preparation Extraction with the 3 piece Adapter Set 3: Piëzo controlled injector with damaged or broken inlet connector : The injector is torn off and injector sheath is stuck in the cylinder head (Supplementary Kit / ) Evaluating the break Tapping M20x1,5 Extracting the sheath Removing the ring Drilling out the sleeve 5: Piëzo or solenoid controlled injector broken or unscrewed in the cylinder head Evaluating the break Removing the nozzle body Tapping M18x1,5 Extracting the remainder of the injector Evaluating the extracted piece Tapping M16x1,5 Extracting the remainder of the injector Recommended Accessories page 6 of 40

7 What Is The Problem? 1 Piëzo controlled injector is stuck. Continue with 1 2 Solenoid controlled injector is stuck. Continue with 2 3 Piëzo controlled injector with a damaged or torn off inlet connector. Continue with 3 page 7 of 40

8 4 The injector is torn off and injector sheath is stuck in the cylinder head. Continue with 4 5 Piëzo or solenoid controlled injector broken or unscrewed in the cylinder head. Continue with 5 page 8 of 40

9 1. Extraction of a piëzo controlled Bosch injector Remove, in preparation, all attachments which are in the way such as: plastic engine cover, wiring harness at the valve cover, fuel injection lines from the rail, air filter housing, circulating air box, etc. Unscrew the respective valve cover bolts on both sides of the concerning injector. 1 2 OPTIONEEL: 1.1. Extraction of a Bosch piëzo controlled injector WITHOUT damaging it. By using the Tensile Force Limiter there is the possibility to extract the injector from the injector shaft without being damaged or torn off. Tensile Force Limiter page 9 of 40

10 Screw-On Adapter on the inlet connector of the injector and tighten it (approx.70nm / Hexagon 8mm) Screw the Tensile Force Limiter on the Adapter and tighten it slightly (Hexagon 24mm) Screw the Extraction Spindle in the Tensile Force Limiter and tighten it (approx. 70Nm / Hexagon 8) page 10 of 40

11 Place the Support Bridge with screwed in Support Legs over the Extraction Spindle and the Tensile Force Limiter Place the Hydraulic Cylinder 12t on the Support Bridge, screw Adapter on the Extraction Spindle and start the extraction procedure. After about 8,0mm is the maximum stroke of the Hydraulic Cylinder reached. Release the pressure, screw in the Adapter and again build up the pressure. (A suitable hydraulic set for this is ) In the injector moves out of the shaft without shearing off the Shear Pins of the Tensile Force Limiter, then continue until the Tensile Force Limiter touches the underside of the Support Bridge. Remove the Tensile Force Limiter and replace it by the Extraction Adapter and Extraction Spindle Place the Hydraulic Cylinder 12t on the Support Bridge, screw Adapter on the Extraction Spindle and extract the injector from the shaft page 11 of 40

12 1.2. Extraction of a Bosch piëzo controlled injector Remove the plastic connector of the injector with a chisel or screwdriver. If the injector is to be removed without damage, there is the possibility to work with the Tensile Force Limiter (not included in the set) Slide on the Open Screw onto the flat areas of the injector Screw Adapter on the inlet connector of the injector and tighten it. (approx. 70Nm / hexagon 8mm) page 12 of 40

13 Screw the Box Nut Adaptor on to Open Screw ( Nm / Hexagon 30mm). fastening torque: min. 100Nm max. 130Nm change over 3-4 times Screw the Adapter with the recess facing downwards on the Extraction Adapter and tighten it. (Hexagon 24mm) Screw the Extraction Spindle in the Adapter and tighten it (Hexagon 8mm). Place the Support Bridge with screwed in Support Legs on the cylinder head page 13 of 40

14 Place the Hydraulic Cylinder 12t on the Support Bridge, screw Adapter on the Extraction Spindle 95mm and start the extraction procedure. After about 8,0mm, the maximum stroke of the Hydraulic Cylinder is reached. Release the pressure, then screw the Adapter in and again build up the pressure. Repeat the procedure until the injector is extracted. (A suitable hydraulic set for this is ) Injector removed completely from the cylinder head? Done! 29 Injector been torn off? Continue with Injector been torn off and the injector sheath is stuck? Continue with 4 page 14 of 40

15 2: Extraction of a solenoid controlled Bosch injector In preparation remove all attachments, which are in the way such as: plastic engine cover, wiring harness at the valve cover, fuel injection lines from the rail, air filter housing, circulating air box, etc Unscrew the respective valve cover bolts on both sides of the concerning injector Remove the solenoid with a spanner, open socket 29mm (not included in the set) or multigrip pliers page 15 of 40

16 2.3. When removing the solenoid, loose parts such as springs, washers and others may fall out! Remove the loose small parts with a magnet Push the three leaf down with a screwdriver, remove the locking ring with a magnet and remove the three leaf and spring Unscrew the screw with the Allen Socket page 16 of 40

17 2.6. Remove all detached parts These parts must be removed Screw the extraction adapter into the injector and tighten it (Hexagon 22) Screw the Sleeve Adaptor on the thread for the solenoid and tighten it (Hexagon 32) page 17 of 40

18 2.9. Screw the Box Nut Adapter on to the Sleeve Adaptor and tighten it. (70-90Nm / Hexagon 32) Screw the Graded Extraction Spindle in the 3-piece Extraction Adapter (grading upwards) and tighten it. (Hexagon 8). Place the Support Bridge with screwed in Support Legs over the extraction spindle on the cylinder head Place the Hydraulic Cylinder 12t on the Support Bridge, screw Adapter on the Extraction Spindle and start the extraction procedure. After about 8.0mm, the maximum stroke of the Hydraulic Cylinder is reached. Release the pressure, screw in the Adapter and again build up the pressure. Repeat the procedure until the injector is extracted from the shaft. (A suitable hydraulic set for this is ) page 18 of 40

19 Injector is removed completely from the cylinder head? Done! Injector been torn off? Continue with 5 Injector been torn off and the injector sheath is stuck? Continue with 4 page 19 of 40

20 3. Extraction of a piëzo controlled injector with a damaged or torn off diesel line connecting thread Example 1 Example Hammer the "Twist Socket" firmly on the protruding part of the injector Unscrew the injector counter clockwise using a socket wrench with square-drive ½" (for example , not included in the set) page 20 of 40

21 3.3. Remove the unscrewed injector from the shaft and proceed with NOTES: page 21 of 40

22 4. The injector is torn off and injector sheath is stuck in the cylinder head. (Supplementary Kit / ) Measure the extracted part of the injector, see figure A". E.g.: piëzo controlled injector (Figure A) The measuring points are identical on a solenoid controlled injector. Approx mm (Figure A) piëzo controlled injector 4.2. Remove with a magnet, the loose small parts from the injector shaft. 67 page 22 of 40

23 4.3. Insert the Pipe Brush as far as possible in the Brush Holder and fix it with two spanners 13 & Clamp the Flexible Shaft with the Brush Holder and Pipe Brush in a drill. Clean the stuck sheath and remove debris using a suction device or compressed air Clamp the Tap in the Holder , lubricate the Tap and cut thread in the sheath page 23 of 40

24 4.6. Remove the swarf using a magnet and clean the cut thread with a suction device or compressed air Screw the spindle in the sheath and tighten it (Hexagon 8) Place the Support Bridge with screwed in Support Legs over the Extraction Spindle on the cylinder head. Place the Hydraulic Cylinder 12t on the Support Bridge, screw Adapter on the Extraction Spindle and start the extraction procedure page 24 of 40

25 4.9. After about 8,0mm, the maximum stroke of the Hydraulic Cylinder is reached. Release the pressure, screw in the Adapter and again build up the pressure. Repeat the procedure until the sheath is extracted. (A suitable hydraulic set for this is ) Check that the snap ring is removed together with the sheath from the injector shaft, if so continue with step IMPORTANT: Work can only be continued, after the snap ring is removed from the injector shaft! Is the snap ring is not removed together with the sheath from the injector shaft, than remove it e.g. with a magnet or a pair of pliers page 25 of 40

26 4.11. Clean the injector shaft until the Guide for Hole Saw can be inserted. Remove debris using a suction device or compressed air Screw the Hole Saw onto the Hole Saw Arbour and tighten it with spanners 15 & 17. Lubricate (with cutting oil or the like) the Arbour and the Hole Saw Slide the Hole Saw Arbour with Mounted Hole Saw , as in picture 89, through the Guide and place the assembly in the injector shaft Cross section of the cylinder head and injector page 26 of 40

27 4.14. Clamp the Hole Saw Arbour in a drill and drill clockwise the injector sleeve out. The correct drilling depth is reached, when the mark on the Hole Saw Arbour protrudes about mm from the Guide IMPORTANT: Remove the hole saw again and again and clean and relubricate the combination Cross section of the cylinder head and injector Detail Remove with a magnet, pliers or other suitable tool, the swarf and loose parts. CONTINUE WITH Cross section of the cylinder head and injector 96 page 27 of 40

28 5. Piëzo or solenoid controlled injector torn off or unscrewed in the cylinder head Injector torn off Injector unscrewed Break Remove the torn off upper part of the injector and the remaining parts (e.g. with a magnet) from the shaft Then determine with the help of a lamp (e.g ), which type of the nozzle bodies the injector contains. A 100 B page 28 of 40

29 If the needle body matches type A: Insert the pin wrench with the thicker end into the injector shaft. If the needle body matches type B: Insert the pin wrench with the thinner end into the injector shaft. A B Insert the pins of the Pin Wrench in the holes of the needle body and loosen it with a ratchet & socket 14mm (type A) or 15mm (type B) at max. 22Nm. Attention: max. torque 22Nm At least 10 revolutions! page 29 of 40

30 Should it not be possible to loosen the needle body with the Pin Wrench with a max. torque of 22 Nm, then the needle body must be loosened in another way by e.g. an air hammer, hammer and chisel, application of heat, etc Remove the needle body using a magnet. With piëzo controlled injectors the nozzle needle body can also be extracted using a Straddling Dowel (see 5.5.1). 105 Needle body completely removed from the cylinder head Remove the needle from the needle body with a magnet Screw the straddling dowel loosely on the pull rod ; the dowel may not expand! 109 page 30 of 40

31 Insert the Pull Rod with the screwed on Straddling Dowel in the injector shaft and push it into the needle body Turn the thumbwheel on the end of the Pull Rod, so that the Straddling Dowel spreads open Draw the needle body from the injector shaft page 31 of 40

32 Removing the injector sleeve part with outside diameter 19mm 5.6. Clean the bore for the nozzle with the Pipe Brush Screw a Sealing Plug on the Setting Tool and close with it the hole to the combustion chamber Clamp the Tap M18x in the Tap Holder and coat the Tap with grease and with a suitable tool 13mm cut thread in the seized sleeve page 32 of 40

33 5.9. Cut the thread into the full length of the injector sleeve. ~20mm Remove the swarf with a magnet Screw the Stepped Extraction Spindle with the wide end first, into the previously cut thread and tighten it (Hexagon 8mm) page 33 of 40

34 5.12. Screw the Adapter with the recess facing downwards on the Extraction Spindle and screw the Extraction Spindle in the Adapter and tighten it. (Hexagon 24/8mm) Place the Support Bridge with screwed in Support Legs , place the Hydraulic Cylinder 12t on the Support Bridge, screw Adapter on the Extraction Spindle 95mm and start the extraction procedure. The injector will start to move upwards. After about 8,0mm the maximum stroke of the Hydraulic Cylinder is reached. Release the pressure, screw the Adapter in and again build up the pressure. Repeat the procedure until the rest of the injector is extracted. (A suitable hydraulic set is ) Injector remains now completely removed from the cylinder head? Done! Sleeve torn off? Continue with 5.14 page 34 of 40

35 IMPORTANT: Before continuing with step 5.15, is it absolutely necessary to check that the entire larger diameter (Ø19) part of the sleeve is removed. This can be determined by comparing the removed part with a new injector. If a part Ø19 sleeve is still remaining in the injector shaft, then steps 5.8 to 5.13 have to be repeated, before continuing with step The M16x1.5 thread in the thinner Ø17 part is not strong enough to extract even a small part of the Ø19 sleeve. for example: Ø17 Ø19 A B This must be removed before continuing with step B C A This part came out during the first extraction attempt. This is the total length of the sleeve Ø19, which has to be removed before continuing with step Injector rest completely removed from the cylinder head, done! Injector sleeve Ø19 part completely removed from the cylinder head? Then continue with step 5.15 page 35 of 40

36 5.15. Clamp in the Tap Holder , coat the Tap M16x with grease and cut, with a suitable tool 13mm, thread in the remaining seized sleeve The maximum depth is reached when the guide of the Tool Holder is flush with the cylinder head Remove the swarf with a magnet page 36 of 40

37 5.18. Screw the Extraction Spindle in the previously cut thread and tighten it (Hexagon 8mm) Screw the Adapter with the recess facing downwards on the Extraction Spindle (Hexagon 24). Screw the Extraction Spindle in the Adapter and tighten it (Hexagon 8mm) Place the Support Bridge with screwed in Support Legs , place the Hydraulic Cylinder 12t on the Support Bridge, screw Adapter on the Extraction Spindle and start the extraction procedure. The injector will start to move upwards. After about 8,0mm, the maximum stroke of the Cylinder is reached. Release the pressure, screw in the Adapter and again build up the pressure. Repeat the procedure until the rest of the injector is extracted. (A suitable hydraulic set is ) Injector rest completely removed from the cylinder head, done! page 37 of 40

38 Recommended Accessories: M9R Supplementary Kit for Tensile Force Limiter Shear Pins Nut M16 for Extraction Spindle Extraction Spindle M16x69mm M9R Supplementary Kit for Removing the Injector Sheath including Cleaning Tools M9R Supplementary Kit for Removing the Injector Sheath Hydraulic Hand Pump Set, 3-pcs Air Hydraulic Foot Pump Set, 4-pcs page 38 of 40

39 Flexible Magnet, 460mm long Injector shaft cleaning set Flexible lamp "BAL" 410mm long, 3,2mm tip diameter Module 1 Brushing Module 1.1 Brushing Plus Module 2 Milling Module 3 Accessories Universal ratchet lever, drive 1/2" ratchet head, 670mm long Open Socket 29.0mm Carbide Burr 12x150mm Cutting grease 300g Carbide Burr 10x150mm Carbide Burr 6x150mm page 39 of 40

40 Bij vragen kunt U ons bereiken in de onderstaande filialen: OOSTENRIJK info@pichler-werkzeug.com Pichler Werkzeug GmbH & Co KG Pacherstraße 20 A-6023 Innsbruck Tel: Fax: ZWITSERLAND pichler@werkzeugag.ch Pichler-Werkzeug AG Rünenbergerstrasse 31 CH-4460 Gelterkinden Tel.: Fax: FRANKRIJK pichler@pichler.fr Pichler Outillage Sarl 19, rue de Reiningue F Wittelsheim Tel.: Fax: BELGIË belgique@pichler.fr Pichler Outillage BVBA Industrieweg 45 B-8800 Roeselare Tel.: Fax: GROOT-BRITTANNIË & IERLAND office@pichler-tools.com Pichler Tools Ltd. Ednaston Business Centre Hollington Lane Ednaston Ashbourne GB-DE6 3AE Tel Mob page 40 of 40