Universal Injector Removal Tool Kit

Transcription

1 Manual Universal Injector Removal Tool Kit for Bosch, Siemens, Denso and Delphi CR injectors /

2 SAFETY NOTICE To understand the functioning of the tools, is it necessary to read the manual in advance! Read these instructions before assembling, during installation and throughout use and in the proper sequence. l Always refer to the OEM manufacturer s instructions and service manuals for the atest data and to maintain the correct sequence. These work instructions and the recommended tools are meant to serve as aides only and are by no means a guarantee for certain results. 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 procedure as per the instructions. The use of the tools should only be carried out by qualified personnel! Pictograms and their meaning: ATTENTION Special caution LIGHT BULB Hint or recommendation Content 1. Bosch & Siemens injectors with removable connecter for the diesel injection line Denso injectors with fixed connecter for the diesel injection line M12x Denso Denso injectors with fixed connecter for the diesel injection line M14x Pulling process using the Swivel Joint and Slide Hammer Adapter external thread M10 : internal thread M Delphi, Bosch & Denso injectors with fixed connecter for the diesel injection line M14x1.5 (piezo controlled) Adapter external thread M10 : external thread M18x Removing the injector with the Adjustable Claw e.g.: Desno, Delphi, etc Recommended accessories

3 UNIVERSAL INJECTOR REMOVAL TOOL KIT / No. Article no. Description Loosening Lever for Bosch/Siemens M12x1.0 external thread Loosening Lever for Adapter Adapter internal thread M14x1.5 : external thread M10 Delphi injectors Loosening Lever for Denso M12x1.5 internal thread Adjustable Claw Swivel Joint Slide Rod 205 mm Adapter external thread M10 : external thread M18x Adapter internal thread M10 : internal thread M Slide Hammer with Slide Rod 115 mm 1 1 3

4 Before starting work Remove in preparation all obstructing parts such as plastic covers, cable looms over the valve cover, injection lines, etc. and remove the retaining fork or the mounting of the injector. 1. Bosch & Siemens injectors with removable connecter for the diesel injection line Loosening Lever with external thread M12x Unscrew the diesel line connector from the injector (hex 13mm) and remove the sealing ring from behind the connector with a magnet. 1 2 Screw the Loosening Lever with external thread M12x in the thread for the connector for the diesel injection line and tighten it with a spanner 17. Try by juddering and levering to release and remove the injector. 3 4 If the injector can not be released, proceed to step 4 on page 6. 4

5 2. Denso injectors with fixed connecter for the diesel injection line M12x1.5 Loosening Lever with internal thread M12x Screw the Loosening Lever on the thread for the diesel injection line and tighten it with a spanner 17. Try by juddering and levering to release and remove the injector. 5 6 If the injector can not be released, proceed to step 4 on page Denso Denso injectors with fixed connecter for the diesel injection line M14x1.5 + Adapter with Loosening Lever Screw the Adapter on the diesel line connector of the injector and tighten it with a spanner 13. Screw the Loosening Lever on the Adapter and tighten it with a spanner 17. Try by juddering and levering to release and remove the injector If the injector can not be released, proceed to step 4 on page 6. 5

6 4. Pulling process using the Swivel Joint and Slide Hammer + Swivel Joint with Slide Hammer Should the pulling with the Loosening Levers not succeed, is it possible to pull the injector by creating an impact force with the Swivel Joint and Slide Hammer. Remove the o-ring from the Loosening Lever and slide the Swivel Joint on the Loosening Lever and fix it with the o-ring. Screw the Loosening Lever on or in the injector and tighten it with a spanner 17. Screw the Slide Hammer with Slide Rod (115 mm) or Slide Hammer (not included in the kit) on the Swivel Joint. Pull by simultaneously juddering the Loosening Lever and hitting with the Slide Hammer the injector out of the shaft. Application example using the Loosening Lever Attention: If the adapter is used with the Loosening Lever and the Swivel Joint must the O-ring be removed

7 5. Adapter external thread M10 : internal thread M12 Adapter TIP: When there is enough space is it possible to use the Slide Bar (205 mm) together with adapter Due to the longer slide path of the Slide Hammer a higher impact force is created. Screw the Adapter on the Swivel Joint slide the Slide Rod (205 mm) through the Slide Hammer and screw it in the Adapter and tighten it with a spanner. Application example using the Loosening Lever with Swivel Joint :

8 6. Delphi, Bosch & Denso injectors with fixed connecter for the diesel injection line M14x1.5 (piezo controlled) Adapter internal thread M14x1.5 : external thread M Screw the Adapter on the diesel line connector of the injector and tighten it with a spanner 13. Screw the Slide Hammer with Slide Rod (115 mm) or Slide Hammer (not included in the kit) on the Swivel Joint. Remove by simultaneously juddering the Loosening Lever and hitting with the Slide Hammer the injector from of the cylinder head TIP: When there is enough space is it possible to use the Slide Rod (205 mm) (see page 7). Due to the longer slide path of the Slide Hammer a higher impact force is created. 8

9 7. Adapter external thread M10 : external thread M18x1.5 Adapter external thread M10: external thread M18x Adapter which makes it possible to use the adapters, e.g. from the set with Slide Hammer or Slide Hammer (not included in the kit). Screw the Adapter in the appropriate adapter and tighten it with a spanner 17. Screw the Slide Rod (115 mm) of Slide Hammer on Adapter and remove by hitting with the Slide Hammer the injector TIP: When there is enough space is it possible to use the Slide Bar (205 mm) (see page 7) Due to the longer slide path of the Slide Hammer a higher impact force is created. 9

10 8. Removing the injector with the Adjustable Claw e.g.: Desno, Delphi, etc. Adjustable Claw Open the Adjustable Claw as far open as possible by unscrewing the cross bolt. Determine the gripping surface on the injector and fix the claw to the injector by tightening the cross bolt (hex 13). Insert the Slide Rod (205 mm) in the Slide Hammer and screw it in the claw and remove by hitting with the Slide Hammer the injector

11 9. Recommended accessories Universal Injector Removal Kit with Hydraulic Open Core Cylinder 12t and Adapter Set (Bosch, Denso, Siemens, Delphi) Hydraulic Set 3 pc. 700 bar Injector Removal Adapter Set 15 pc. Slide Hammer 8.5 kg external thread M18x1.5, stroke 400 mm Slide Hammer 0.7 kg internal thread M10, stroke: 140 mm Universal Injector Shaft Cleaning Kit complete with 5 modules Glowplug Hole Brushes Set 14 pc Injector Needle Puller E Universal Injector Copper Washer Remover Cotton Swabs Set SWAB-EEZ Air Hydraulic Pump 700 bar with Hydraulic Pressure Gauge, 3 m Hose and Ball Valve

12 AUSTRIA PICHLER Werkzeug GmbH & CoKG Pacherstrasse 20 A-6023 Innsbruck GERMANY PICHLER Werkzeug GmbH Zugspitzstrasse 33 D Garmisch-Partenkirchen SWITZERLAND PICHLER Werkzeug AG Rünenbergerstraße 31 CH-4460 Gelterkinden FRANCE PICHLER Outillage Sàrl 19a, rue de Reiningue F Wittelsheim BELGIUM PICHLER Outillage BVBA Industrieweg 45 B-8800 Roeselare GREAT BRITAIN & IRELAND PICHLER TOOLS LTD Ednaston Business Centre Hollington Lane, Ednaston Ashbourne DE6 3AE Stand: 08/2015 Version: