Injector Extraction Kit - SM PRODUKTER

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Work Instructions

Injector Extraction Kit for the M9R / M9T 60385095

Tensile Force Limiter 60385229


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


M9R Injector Extraction Kit 60385095

N° P/n Description 60385095 60385105 60385240* 1 6038411 Hydraulic Cylinder 12 t. 1 - - 2 60384425 Pin Wrench 1 1 1 3 60385211 Tap M18x1.5 1 1 1 4 60385214 Tool Holder with Guide for Tap M18x1.5 1 1 1 5 60385248 Extraction Spindle M18x1.5 Stepped to M16x1.5 1 1 - 6 60385212 Tap M16x1.5 1 1 - 7 60385213 Tool Holder with Guide for Tap M16x1.5 1 1 - 8 60385236 Extraction Spindle M16x1.5x208 1 1 - 9 60385225 Support Bridge Leg 2 2 -

10 60385220 Support Bridge 1 1 - 11 60385210 Adapter M16x2 1 1 - 12 60385218 Straddling Dowel (packing unit: 4 pcs) 1 1 - 13 60385217 Pull Rod for Straddling Dowel 1 1 - 14 60385235 Box Nut Adaptor 1 1 - 15 60390100 Sealing Plugs with Setting Tool 10mm 1 1 1 16 60384172 Allen Socket 10 with Hole (Custom made) 1 1 1 17 60384414 Extraction Adapter for Solenoid Controlled Injectors 1 1 1 18 60384413 Box Nut Adaptor for Solenoid Controlled Injectors 1 1 1 19 60384417 Sleeve Adaptor for Solenoid Controlled Injectors 1 1 1 20 60385051 Adapter M18x1.5 1 1 1 21 9130032 Stud Remover „Twist Socket“ 1/2" Drive 1 1 1 22 60385243 Extraction Adapter for Piëzo Controlled Injectors 1 1 - 23 60385230 Open Screw 1 1 - 24 60385215 Extraction Adapter M16x2 to M16x1.5 1 1 - 25 9049027 Pipe Brush 1 1 1 26 60385238 Extraction Spindle M16x2x95mm 1 1 -

* Supplementary kit to 60385195 with foam insert.


M9R Injector Extraction Supplementary Kit 60385190

N° P/n Description 60385190 60385200 1 9039034 Flexible Bit Holder 1/4 " 1 - 2 60385201 Tap M20x1,5 1 1 3 60385202 Tap Holder 1 1 4 9039036 Brush Holder 1 - 5 60385249 Extraction Spindle Stepped M20x1,5 / M16 1 1 6 60385204 Hole Saw Arbour 1 1 7 9039027 Tube Brush Ø26mm 2 - 8 30301900 Hole Saw 4 4 9 60385203 Hole Saw Guide 1 1

M9R Injector Extraction Supplementary Tensile Force Limiter 60385229

N° P/n Description 60385229 1 60385227 Tensile Force Limiter Top Section 1 2 603852331 Shear Pin 6h8 x35mm 2 3 60385223 O-Ring NNR70 32x3 1 4 60385228 Tensile Force Limiter Bottom Section 1


Contents: Page

What’s the problem? 6-7

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 14-18

Preparation

Extraction with the 3 piece Adapter Set

3: Piëzo controlled injector with damaged or broken inlet connector 19-20

4: The injector is torn off and injector sheath is stuck in the cylinder head (Supplementary Kit 603852005/ 60385200)

21-26

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 27-36

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 37-38


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


5 Piëzo o r solenoid controlled injector broken or unscrewed in the cylinder head . Continue with 5

4 The injector is torn off and injector sheath is stuck in the cylinder head . Continue with 4


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.

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 60385229

3 4

1 2


1.1.1. Screw-On Adapter 60385243 on the inlet connector of the injector and tighten it (approx.70Nm / Hexagon 8mm) .

1.1.2. Screw the Tensile Force Limiter 60385229 on the Adapter 60385243 and tighten it slightly (Hexagon 24mm) .

1.1.3. Screw the Extraction Spindle 60385237 in the Tensile Force Limiter 60385229 and tighten it (approx. 70Nm / Hexagon 8).

5 6

9 10

7 8


1.1.4. Place the Support Bridge 60385220 with screwed in Support Legs 60385225 over the Extraction Spindle and the Tensile Force Limiter.

1.1.5. Place the Hydraulic Cylinder 12t 6038411 on the Support Bridge, screw Adapter 60385210 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 80255500)

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 60385215 and Extraction Spindle 60385238. Place the Hydraulic Cylinder 12t 6038411 on the Support Bridge, screw Adapter 60385210 on the Extraction Spindle and extract the injector from

the shaft.

11 12

14 13


1.2. Extraction of a Bosch piëzo controlled injector 1.2.1. 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 60385229 (not included in the set).

1.2.2. Slide on the Open Screw 60385230 onto the flat areas of the injector.

1.2.3. Screw Adapter 60385243 on the inlet connector of the injector and tighten it. (approx. 70Nm / hexagon 8mm)

19 20

15 16

17 18


1.2.4. Screw the Box Nut Adaptor 60385235 on to Open Screw 60385230. (100 – 130Nm / Hexagon 30mm).

1.2.5. Screw the Adapter 60385215 with the recess facing downwards on the Extraction Adapter 60385243 and tighten it.

(Hexagon 24mm) .

1.2.6. Screw the Extraction Spindle 60385238 in the Adapter 60385215 and tighten it (Hexagon 8mm) . Place the Support Bridge 60385220 with screwed in Support Legs 60385225 on the cylinder head.

23 24

25 26

fastening torque: min. 100Nm max. 130Nm change over 3 -4 times

22 21


1.2.7. Place the Hydraulic Cylinder 12t 6038411 on the Support Bridge, screw Adapter 60385210 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 80255500)

27 28

Injector removed completely from the cylinder head? Done!

29

Injector been torn off? � Continue with 5

30

Injector been torn off and the injector sheath

is stuck? Continue with 4

31


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.

2.1. Unscrew the respective valve cover bolts on both sides of the concerning injector.

2.2. Remove the solenoid with a spanner, open socket 29mm (not included in the set) or multigrip pliers.

32 33

33 34


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.

2.4. Push the three leaf down with a screwdriver, remove the locking ring with a magnet and remove the three leaf and spring.

2.5. Unscrew the screw with the Allen Socket 60384172.

35 36

37 38

39 40 41


2.6. Remove all detached parts.

2.7. Screw the extraction adapter 60384414 into the injector and tighten it (Hexagon 22) .

2.8. Screw the Sleeve Adaptor 60384417 on the thread for the solenoid and tighten it (Hexagon 32) .

42

These parts must be removed.

43

44 45

46 47


2.9. Screw the Box Nut Adapter 60384416 on to the Sleeve Adaptor 60384417 and tighten it. (70-90Nm / Hexagon 32)

2.10. Screw the Graded Extraction Spindle 60385248 in the 3-piece Extraction Adapter (grading upwards) and tighten it. (Hexagon 8). Place the Support Bridge 60385220 with screwed in Support Legs 60385225 over the extraction spindle on the cylinder head.

2.11. Place the Hydraulic Cylinder 12t 6038411 on the Support Bridge, screw Adapter 60385210 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 80255500).

52 53

50 51

48 49


Injector is removed completely from the cylinder head? Done!

54

Injector been torn off? Continue with 5

55

Injector been torn off and the injector sheath is stuck? Continue with 4

56


3. Extraction of a piëzo controlled injector with a dam aged or torn off

diesel line connecting thread

3.1. Hammer the "Twist Socket" 9130032 firmly on the protruding part of the injector.

3.2. Unscrew the injector counter clockwise using a socket wrench with square-drive ½" (for example 9411000, not included in the set).

Example 1

57

Example 2

58

61 62

59 60


3.3. Remove the unscrewed injector from the shaft and proceed with 5.

NOTES:

63 64


4. The injector is torn off and injector sheath is stuck in the cylinder head. (Supplementary Kit 603852005/ 60385200)

4.1. Measure the extracted part of the injector, see figure “A".

4.2. Remove with a magnet, the loose small parts from the injector shaft.

67

66 65

E.g.: piëzo controlled injector (Figure A) The measuring points are identical on a solenoid controlled injector.

(Figure A) piëzo controlled injector

Approx. 51 – 53 mm


4.3. Insert the Pipe Brush 9039027 as far as possible in the Brush Holder 9039036 and fix it with two spanners 13 & 14.

4.4. Clamp the Flexible Shaft 9039034 with the Brush Holder 9039036 and Pipe Brush 9039027 in a drill. Clean the stuck sheath and remove debris using a suction device or compressed air.

4.5. Clamp the Tap 60385201 in the Holder 60385202, lubricate the Tap and cut thread in the sheath.

68 69

70 71

72

Cross section of the cylinder head and injector

73


4.6. Remove the swarf using a magnet and clean the cut thread with a suction device or compressed air.

4.7. Screw the spindle 60385249 in the sheath and tighten it (Hexagon 8).

4.8. Place the Support Bridge 60385220 with screwed in Support Legs 60385225 over the Extraction Spindle on the cylinder head. Place the Hydraulic Cylinder 12t 6038411 on the Support Bridge, screw Adapter 60385210 on the Extraction Spindle and start the extraction procedure.

74 75

76 77

78 79


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 80255500).

4.10. Check that the snap ring is removed together with the sheath from the injector shaft, if so continue with step 4.11.

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.


80 81

82


83 84


4.11. Clean the injector shaft until the Guide for Hole Saw 60385203 can be inserted. Remove debris using a suction

device or compressed air.

4.12. Screw the Hole Saw 30301900 onto the Hole Saw Arbour 60385204 and tighten it with spanners 15 & 17. Lubricate (with cutting oil or the like) the Arbour and the Hole Saw.

4.13. Slide the Hole Saw Arbour 60385204 with Mounted Hole Saw 30301900, as in picture 89, through the Guide 60385203 and place the assembly in the injector shaft.

86 85

87 88


90 89


4.14. Clamp the Hole Saw Arbour 60385204 in a drill and drill clockwise the injector sleeve out. The correct drilling depth is reached, when the mark on the Hole Saw Arbour 60385204 protrudes about 1 - 1.5 mm from the Guide 60385203.

IMPORTANT: Remove the hole saw again and again and clean and relubricate the combination.

4.15. Remove with a magnet, pliers or other suitable tool, the swarf and loose parts.

CONTINUE WITH 5.2

91


92

93

Detail

94


95


96


5. Piëzo or solenoid controlled injector torn off or unscrewed in the cylinder head

5.1. Remove the torn off upper part of the injector and the remaining parts (e.g. with a magnet) from the shaft.

5.2. Then determine with the help of a lamp (e.g. 40103000), which type of the nozzle bodies the injector contains.

Injector torn off

Break Bruchstelle

Cross section of the cylinder head and injector Zylinderkopf und Injektor im Schnitt

97

Injector unscrewed


98


99


100

A

B Cross section of the cylinder head and injector

100


If the needle body matches type A : Insert the pin wrench 60384425 with the thicker end into the injector shaft.

If the needle body matches type B : Insert the pin wrench 60384425 with the thinner end into the injector shaft.

5.3. Insert the pins of the Pin Wrench 60384425 in the holes of the needle body and loosen it with a ratchet & socket

14mm (type A) or 15mm (type B) at max. 22Nm .

B

102

A

101

Attention: max. torque 22Nm


103

At least 10 revolutions!

104


5.3.1. 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.

5.4. 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).

5.5.1. Remove the needle from the needle body with a magnet.

5.5.2. Screw the straddling dowel 60385218 loosely on the pull rod 60385217; the dowel may not expand!


105

Needle body completely removed from the cylinder head

106


107 108

109


5.5.3. Insert the Pull Rod with the screwed on Straddling Dowel in the injector shaft and push it into the needle body.

5.5.4. Turn the thumbwheel on the end of the Pull Rod, so that the Straddling Dowel spreads open.

5.5.5. Draw the needle body from the injector shaft.


110


111

112

113 114


Removing the injector sleeve part with outside diameter 19mm

5.6. Clean the bore for the nozzle with the Pipe Brush 9049027.

5.7. Screw a Sealing Plug on the Setting Tool 60390100 and close with it the hole to the combustion chamber.

5.8. Clamp the Tap M18x1.5 60385211 in the Tap Holder 60385214 and coat the Tap with grease and with a suitable tool 13mm cut thread in the seized sleeve.

Cross section of the cylinder head and injector Cross section of the cylinder head and injector

115 116


119 120

Cross section of the cylinder head and injector Cross section of the cylinder head and injector

117 118


5.9. Cut the thread into the full length of the injector sleeve.

5.10. Remove the swarf with a magnet.

5.11. Screw the Stepped Extraction Spindle 60385248 with the wide end first, into the previously cut thread and tighten it (Hexagon 8mm).


126 125


123 124

~20mm


121 122


5.12. Screw the Adapter 60385215 with the recess facing downwards on the Extraction Spindle 60385248 and screw the Extraction Spindle 60385238 in the Adapter and tighten it. (Hexagon 24/8mm)

5.13. Place the Support Bridge 60385220 with screwed in Support Legs 60385225, place the Hydraulic Cylinder 12t 6038411 on the Support Bridge, screw Adapter 60385210 on the Extraction Spindle „95mm“60385238 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 80255500)

Injector remains now completely removed from the cylinder head? Done!

Sleeve torn off? Continue with 5.14

130 131

128 127

127


IMPORTANT: 5.14. 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 5.15. 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:

A

Ø19 Ø17

B

A B

C

This part came out during the first extraction attempt.

This m ust be removed before continuing with step 5.15.

This is the t otal length of the sleeve Ø19, which has to be removed before continuing with step 5.15.

132 133

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

134 135


5.15. Clamp in the Tap Holder 60385213, coat the Tap M16x1.5 60385212 with grease and cut, with a suitable tool 13mm, thread in the remaining seized sleeve.

5.16. The maximum depth is reached when the guide of the Tool Holder is flush with the cylinder head.

5.17. Remove the swarf with a magnet.


136 137


138 139

Cross section of the cylinder head and injector Zylinderkopf und Injektor im Schnitt

140 141


5.18. Screw the Extraction Spindle 60385236 in the previously cut thread and tighten it (Hexagon 8mm) .

5.19. Screw the Adapter 60385215 with the recess facing downwards on the Extraction Spindle 60385236 (Hexagon 24). Screw the Extraction Spindle 60385238 in the Adapter and tighten it (Hexagon 8mm) .

5.20. Place the Support Bridge 60385220 with screwed in Support Legs 60385225, place the Hydraulic Cylinder 12t 6038411 on the Support Bridge, screw Adapter 60385210 on the Extraction Spindle 60385238 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 80255500).


142 143

145 144

Injector rest completely removed from the cylinder head, done! 146

147


Recommended Accessories:

60385240

M9R Supplementary Kit for 60385195

60385229 60385233 Tensile Force Limiter Shear Pins

60385245 Nut M16 for Extraction Spindle

60385237 Extraction Spindle M16x69mm

60385190

M9R Supplementary Kit for Removing the Injector Sheath including Cleaning Tools

60385200

M9R Supplementary Kit for Removing the Injector Sheath

80255500

Hydraulic Hand Pump Set, 3-pcs

80255510

Air Hydraulic Foot Pump Set, 4-pcs


52601040

Flexible Magnet, 460mm long

9038100

Injector shaft cleaning set

Module 1 Brushing 9038010

Module 1.1 Brushing Plus 9038011

Module 2 Milling 9038020

Module 3 Accessories 9038030

40103000

Flexible lamp "BAL" 410mm long, 3,2mm tip diameter

7560010 + 75005160 Universal ratchet lever,

drive 1/2" ratchet head, 670mm long

6038422

Open Socket 29.0mm

67050120 Carbide Burr 12x150mm



60200035

Cutting grease 300g


Bij vragen kunt U ons bereiken in de onderstaande filialen:

OOSTENRIJK [email protected] Pichler Werkzeug GmbH & Co KG Pacherstraße 20 A-6023 Innsbruck Tel: +43 512 344552 Fax: +43 512 393762

ZWITSERLAND [email protected] Pichler-Werkzeug AG Rünenbergerstrasse 31 CH-4460 Gelterkinden Tel.: +41 61 981 33 55 Fax: +41 61 981 12 86

FRANKRIJK [email protected] Pichler Outillage Sarl 19, rue de Reiningue F-68310 Wittelsheim Tel.: +33 3 89 55 15 96 Fax: +33 3 89 55 24 38

BELGIË [email protected] Pichler Outillage BVBA Industrieweg 45 B-8800 Roeselare Tel.: +32 495 400810 Fax: +32 51 250829

GROOT-BRITTANNIË & IERLAND

[email protected] Pichler Tools Ltd. Ednaston Business Centre Hollington Lane Ednaston Ashbourne GB-DE6 3AE Tel. +44 1335 368010 Mob. +44 7885 244338

www.pichler-werkzeug.com

Injector Extraction Kit - SM PRODUKTER

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Transcript of Injector Extraction Kit - SM PRODUKTER