Universal Injector Removal Tool Kitfor Bosch, Siemens, Denso and Delphi CR injectors 60384435 / 60384535

Manual

2

SAFETY NOTICE

Content

Read these instructions before assembling, during installation and throughout use and in the proper sequence.

Always refer to the OEM manufacturer’s instructions and service manuals for thel 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.

Theuseofthetoolsshouldonlybecarriedoutbyqualifiedpersonnel!

To understand the functioning of the tools,is it necessary to read the manual in advance!

Pictograms and their meaning:

ATTENTIONSpecial caution

LIGHT BULBHint or recommendation

1. Bosch & Siemens injectors with removable connecter for the diesel injection line ..........4

2. DensoinjectorswithfixedconnecterforthedieselinjectionlineM12x1.5 .......................5

3. DensoDensoinjectorswithfixedconnecterforthedieselinjectionlineM14x1.5 ...........5

4. Pulling process using the Swivel Joint and Slide Hammer ...............................................6

5. AdapterexternalthreadM10:internalthreadM12 ..........................................................7

6. Delphi, Bosch & Denso injectors withfixedconnecterforthedieselinjectionlineM14x1.5(piezocontrolled) ....................8

7. Adapter60384404externalthreadM10:externalthreadM18x1.5 ................................9

8. RemovingtheinjectorwiththeAdjustableClawe.g.:Desno,Delphi,etc. .....................10

9. Recommended accessories ...........................................................................................11

1. 2. 3. 6.

3

10

10

2

6

5

73

1 4

9

8

UNIVERSAL INJECTOR REMOVAL TOOL KIT

60384435 / 60384535

No. Article no. Description 60384435 60384535

1 9038437 LooseningLeverforBosch/SiemensM12x1.0externalthread 1 1

2 9038439 LooseningLeverforAdapter9039432 1 1

3 9038432 AdapterinternalthreadM14x1.5:externalthreadM10 Delphi injectors 1 1

4 9038438 LooseningLeverforDensoM12x1.5internalthread 1 1

5 60384432 Adjustable Claw 1 -

6 9038440 Swivel Joint 1 1

7 60384431 SlideRod205mm 1 1

8 60384404 AdapterexternalthreadM10:externalthreadM18x1.5 1 1

9 60384419 AdapterinternalthreadM10:internalthreadM12 1 1

10 60390750 SlideHammerwithSlideRod115mm 1 1

4

1

3

2

4

Before starting workRemove 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

Screw the Loosening Lever with external thread M12x1 9038437 1 in the thread for the connector forthedieselinjectionlineandtightenitwithaspanner17.Trybyjudderingandleveringtoreleaseandremove the injector.

If the injector can not be released, proceed to step 4 on page 6.

Unscrewthediesellineconnectorfromtheinjector(hex13mm)andremovethesealingringfrombe-hind the connector with a magnet.

Loosening Lever with external thread M12x1 9038437 1

5

5

87

6

9

2. DensoinjectorswithfixedconnecterforthedieselinjectionlineM12x1.5

3. DensoDensoinjectorswithfixedconnecterforthedieselinjectionlineM14x1.5

+

If the injector can not be released, proceed to step 4 on page 6.

If the injector can not be released, proceed to step 4 on page 6.

Screw the Loosening Lever 9038438 4 on the thread for the diesel injection line and tighten it with a spanner17.Trybyjudderingandleveringtoreleaseandremovetheinjector.

Screw the Adapter 9038432 3 on the diesel line connector of the injector and tighten it with a span-ner13.Screw theLoosening Lever 9038439 2 on theAdapterand tighten itwithaspanner17. Try by juddering and levering to release and remove the injector.

Loosening Lever with internal thread M12x1.5 9038438 4

Adapter 9038432 3 with Loosening Lever 9038439 2

6

4. Pulling process using the Swivel Joint and Slide Hammer

10

12

11

13

Remove the o-ring from the Loosening Lever and slide the Swivel Joint 9038440 6 on the Loose-ningLeverandfixitwiththeo-ring.ScrewtheLooseningLeveronorintheinjectorandtightenitwithaspanner17.

Screw the Slide Hammer 60390750 10 withSlideRod(115mm)orSlide Hammer 1030210(notin-cludedinthekit)ontheSwivelJoint.PullbysimultaneouslyjudderingtheLooseningLeverandhittingwith the Slide Hammer the injector out of the shaft. ApplicationexampleusingtheLooseningLever 9038437 1

Swivel Joint 9038440 6 with Slide Hammer 60390750 10

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.

Attention: If the adapter 9038432 3 is used with the Loosening Lever 9038439 2 and the Swivel Joint 9038440 6 must the O-ring be removed.

+

7

5. AdapterexternalthreadM10:internalthreadM12

Screw the Adapter 60384419 9 on the Swivel Joint 9038440 6 slide the Slide Rod (205mm)60384431 7 through the Slide Hammer 60390750 10 and screw it in the Adapter 60384419 9 and tighten it with a spanner.

14 15 16

Adapter 60384419 9

Applicationexampleusingthe Loosening Lever 9038437 1 with Swivel Joint 9038440 6 :

TIP:Whenthereisenoughspaceisitpossibleto use the Slide Bar (205 mm) 60384431 7 together with adapter 60384419 9 . Due to the longer slide path of the Slide Hammer a higher impact force is created.

8

1817 19

6. Delphi, Bosch & Denso injectors with fixedconnecterforthedieselinjectionlineM14x1.5(piezocontrolled)

Screw the Adapter 9038432 3 on the diesel line connector of the injector and tighten it with a spanner13.

Screw the Slide Hammer 60390750 10 withSlideRod (115mm)orSlide Hammer 1030210 (notincludedinthekit)ontheSwivelJoint.RemovebysimultaneouslyjudderingtheLooseningLeverandhitting with the Slide Hammer the injector from of the cylinder head.

Adapter internal thread M14x1.5 : external thread M10 9038432 3

TIP:When there is enough space is it possible to use the Slide Rod (205 mm) 60384431 7 (see page 7).Due to the longer slide path of the Slide Hammer a higher impact force is created.

9

7. Adapter60384404externalthreadM10:externalthreadM18x1.5

Screw the Adapter 60384404 8 intheappropriateadapterandtightenitwithaspanner17.ScrewtheSlideRod(115mm)ofSlide Hammer 60390750 10 on Adapter 60384404 8 and remove by hitting with the Slide Hammer the injector.

Adapter which makes it possible to use the adapters, e.g. from the set 60384660 with Slide Hammer 60390750 10 or Slide Hammer 1030210(notincludedinthekit).

Adapter external thread M10: external thread M18x1.5 60384404 8

TIP: WhenthereisenoughspaceisitpossibletousetheSlide Bar (205 mm) 60384431 7 . (see page 7)Due to the longer slide path of the Slide Hammer a higher impact force is created.

20 21 22

10

8. Removing the injector with the Adjustable Claw e.g.: Desno, Delphi, etc.

Adjustable Claw 60384432 5

Open the Adjustable Claw 60384432 5 as far open as possible by unscrewing the cross bolt. De-terminethegrippingsurfaceontheinjectorandfixtheclawtotheinjectorbytighteningthecrossbolt(hex13).

Insert the Slide Rod (205 mm) 60384431 7 in the Slide Hammer 60390750 10 and screw it in the claw and remove by hitting with the Slide Hammer the injector.

23 24

11

Universal Injector Removal KitwithHydraulicOpenCoreCylinder12tandAdapterSet(Bosch,Denso,Siemens,Delphi)

60385445

Injector Removal Adapter Set 15 pc.

60384660

Universal Injector Shaft Cleaning Kit complete with 5 modules

9038100

Slide Hammer 8.5 kg externalthreadM18x1.5,stroke400mm

6148800

Slide Hammer 0.7 kg internalthreadM10,stroke:140mm

1030210

Hydraulic Set 3 pc. 700 bar

80255500

Universal Injector Copper Washer Remover

6039070

Glowplug Hole Brushes Set14pc

90490300

Injector Needle Puller

6038472E

Cotton Swabs Set „SWAB-EEZ“

9495291

Air Hydraulic Pump700 bar with Hydraulic Pressure Gauge,3 m Hose and Ball Valve

80255575

9. Recommended accessories

Stand: 08/2015 Version: 1.0

AUSTRIA info@pichler-werkzeug.com

+43 512 344552PICHLERWerkzeugGmbH&CoKGPacherstrasse20A-6023Innsbruck

GERMANY info@pichler-werkzeug.de

+49 8821 6869780PICHLERWerkzeugGmbHZugspitzstrasse33D-82467Garmisch-Partenkirchen

SWITZERLANDpichler@werkzeugag.ch

+41 61 981 33 55PICHLERWerkzeugAGRünenbergerstraße31CH-4460 Gelterkinden

FRANCE pichler@pichler.fr +33 389 551 596

PICHLER Outillage Sàrl19a,ruedeReiningueF-68310Wittelsheim

BELGIUM belgique@pichler.fr +32 495 400810

PICHLER Outillage BVBAIndustrieweg 45B-8800 Roeselare

GREAT BRITAIN & IRELAND office@pichler-tools.com +44 1335 360759

PICHLER TOOLS LTD Ednaston Business Centre Hollington Lane, Ednaston Ashbourne DE6 3AE

www.pichler-werkzeug.com· www.pichler-tools.com · www.pichler-outillage.com