DIESEL INJECTOR MASTER KIT
Contents
1. INSTRUCTIONS FOR DIESEL INJECTOR MASTER KIT MODEL No VS2064 Thank you for purchasing a Sealey product Manufactured to a high standard this product will if used according to these instructions and properly maintained give you years of trouble free performance IMPORTANT PLEASE READ THESE INSTRUCTIONS CAREFULLY NOTE THE SAFE OPERATIONAL REQUIREMENTS WARNINGS amp CAUTIONS USE THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED FAILURE TO DO SO MAY CAUSE DAMAGE AND OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE 1 SAFETY Read Instruction Wear Eye Manual Protection WARNING Ensure Health and Safety local authority and general workshop practice regulations are adhered to when using tools WARNING Always use caution when working around fuel systems The fuel in the fuel rail may be pressurised even if the engine is not running IMPORTANT These instructions are provided as a guide only Always refer to the vehicle manufacturer s service instructions or a proprietary manual to establish the current procedure and data also any warnings or cautions particular to the vehicle DO NOT use the set if any parts are missing or damaged DO NOT use this tool for any purpose other than that for which it is designed Switch off the vehicle s ignition and disconnect the battery before commencing work under the bonnet You must follow the vehicle s service m2. anual cautions when working around the air bag system If the cautions are not followed the air bag may deploy unexpectedly even after the ignition is turned OFF resulting in personal injury Never lay tools on the vehicle s battery This may short the terminals together causing harm to yourself the tools or the battery Operate in a well ventilated area Do not inhale fuel vapours Wear approved eye protection A full range of personal safety equipment is available from your Sealey dealer Wear suitable clothing to avoid snagging Do not wear jewellery and tie back long hair Keep children and other unauthorised persons away from the working area Keep yourself tools and test equipment away from hot engine parts Always keep a fire extinguisher that is suitable for fuel electrical chemical fires close by NEVER smoke or have open flames near vehicle Always relieve fuel pressure before disconnecting fuel lines from injectors Cover fuel line fittings when connecting or disconnecting fuel lines to guard against high pressure leaks Avoid contact with fuel Clean up all fuel spills immediately and dispose of all waste according to local regulations Maintain the tool components in good and clean condition for best and safest performance When work on the vehicle is finished ensure all connections on the vehicle are restored and that there are no tools left in the engine bay Replace tools in the carrying case and store in a safe dry chi
3. e injector 4 3 4 3 1 4 3 2 4 4 4 4 1 4 5 4 5 1 4 5 2 4 5 3 4 5 4 E Use of internal adaptor fig 4 Remove the internal parts from the injector to gain access to use the security hex key It may be necessary to remove the injector vanes by force Insert the security hex into the inner sleeve see D Turn the security hex anti clockwise using a 21mm socket to remove the inner sleeve Screw the appropriate internal adaptor into the threads of the injector and tighten with a suitable spanner see E Use of claw adaptor fig 5 Slide the forks of the claw adaptor onto the flats machined into the injector body see F Removing the injector Screw the slide hammer assembly handle shaft and sliding hammer securely onto the adaptor The injector can now be removed using reasonable force on the slide hammer Be prepared for the sudden release of the injector from the cylinder head If the injector cannot be removed it may be necessary to consult a main dealer or a diesel specialist to avoid damage to the engine When an injector has been removed it is recommended that only a new or refurbished injector is fitted Follow manufacturers fitting and safety instructions Screw hammer shaft adaptor Attach to slide 4 i I into inner sleeve threads Slide forks onto flats beneath collar hammer and extract injector Environmental Protection Recycle unwanted materials instead of d
4. isposing of them as waste All tools accessories and packaging should be sorted taken to a recycling centre and disposed of in a manner which is compatible with the environment When the product becomes completely unserviceable and requires disposal drain off any fluids if applicable into approved containers and dispose of the product and the fluids according to local regulations NOTE It is our policy to continually improve products and as such we reserve the right to alter data specifications and component parts without prior notice IMPORTANT No liability is accepted for incorrect use of this product WARRANTY Guarantee is 12 months from purchase date proof of which will be required for any claim INFORMATION For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address including postcode Sole UK Distributor Sealey Group Kempson Way Suffolk Business Park Bury St Edmunds Suffolk a 01284 757500 4 www sealey co uk w Web IP32 7AR Jack Sealey Ltd Original Language Version 01284 703534 sales sealey co uk
5. ldproof location 2 INTRODUCTION Suitable for the removal of Bosch Delphi Denso Siemens and Pumpe Duse diesel injectors Set includes keys and deep open profile sockets used to dismantle injectors plus a selection of adaptors for attaching the slide hammer securely to the body of the injector Ball joint and choice of two sizes of slide hammer allow access in confined areas if required 3 CONTENTS Slide Hammers 1 3kg with 150mm Shaft 4kg with 400mm Shaft 4kg Slide Hammer Handle Flexible Joint Security Hex Key 10mm Adaptors Male 10x1 5 16x1 5 17x1 0 20x1 0 25x1 0 27x1 0mm Adaptors Female 14x1 5 27x1 0mm 3pc Adaptors Hexagonal 17mm 10x1 5 Female 21mm 14x1 5 Female Adaptors C and J Pump Duse Claw Adaptor Injector Cap Sockets 1 2 Sq Drive 25 27 29 30mm Ly m lt S x KSSS SSASSN RRA Extraction Extraction using using external internal thread on thread injector within m injector Ei i l O NOTE Assemble extractors j to the injector first then attach the slide hammer Jack Sealev Ltd Original Language Version 3 ASSEMBLY 3 1 Assemble the Injector Puller as shown in fig 2 3 2 Use external adaptor when the injector is being extracted using the external thread revealed when the injector cap has been removed 3 3 Use one of the conventional adaptors when the injector is being 4 OPERATION NOTE The technique required for removal of the inject
6. or will depend on which system is fitted to the vehicle Always use an external adaptor first if possible If by using reasonable force the injector cannot be removed use an internal adaptor or claw adaptor 4 1 Before working on the fuel system make sure that the fuel system is NOT pressurised Refer to the manufacturer s instruction manual on how to de pressurise the system 4 1 1 Disconnect the injector wires and connections as per the manufacturer s instructions 1 2 Remove any carbon build up from around the injector 1 3 Remove the cap from the injector using the appropriate size socket Refer to fig 3 A 4 2 Use of external adaptor fig 3 4 2 1 Identify the external thread adaptor and separate the inner black part from the outer silver part by removing the screw from the top of the adaptor 4 2 2 Position the black part inside the top of the injector see B then place the silver part over it and screw it down firmly onto the external threads revealed when the cap was removed 4 2 3 Install the screw securely thus locking the adaptor parts tightly together with the injector thread and wall in between This ensures a more secure fastening and reduces damage to the injector threads Unscrew D injector cap Assemble internal adaptor sieays to injector from injector Extract slide hammer and extract injector extracted using the internal thread revealed when the inner sleeve has been removed from th
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