Common Rail Injector Repair Guideline

MarbedBook2011Common Rail Injectors Common Rail Injectors Injectors equipment www.marbed.com PROFESSIONAL DIESEL SERVICE TOOLS Common Rail Injectors Injector equipment COMMON RAIL INJECTORS Pullers Tools for nozzle replacement Wrenches for nozzle nuts Ultrasonic cleaner Solenoid wrenches Dismounting tools Repairing tools Reamers Copper washers 3-6 7 - 12 13 14 15 16 - 18 19 - 23 24 25 - 26 5 mm.) ALLOWED (NO PART No. 8100-A (NO PART No. ALLOWED 8100 (NO PART No. .PROFESSIONAL DIESEL SERVICE TOOLS 8100 Pullers for Common Rail Injectors 8099-T 8099-N 8099-AN BH 0 986 612 727 8099-T ALLOWED 8099-N 8099-CN 8099 BH 0 986 612 604 (NO PART No.) ALLOWED (NO PART No. SERIE E etc.) ALLOWED (NO PART No.R01 .) ALLOWED 8099-C (NO PART No.) Puller for 8099 7 mm.) Blow puller for common rail injectors (BH 0 445 110 15) on MERCEDES CLASSE A.) (NO PART No.) Reduction puller to extend 8099 application on ALFA 156 ALLOWED 2.) Reduction puller to extend 8099 application on BOSCH injectors (mounted on IVECO DAILY) ALLOWED 8099-CT Adaptor for 8099-C 320.) ALLOWED (NO PART No.3 (NO PART No. ) ALLOWED (NO PART No.PULLERS FOR COMMON RAIL INJECTORS PROFESSIONAL DIESEL SERVICE TOOLS 8099-AN BH 0 986 612 727 8099-AC 8099-A BH 0 986 612 728 8099-N 8099-CN ALLOWED ALLOWED (NO PART No.) Reduction puller to extend 8099 universal application 8099-SN ALLOWED (NO PART No.) Puller bush for Denso CR injectors 320.) ALLOWED (NO PART No.) Reduction puller to extend 8099-A application on Unit Injection System installed on VW LUPO 8099-D 8099-E BH 0 986 612 782 ALLOWED (NO PART No.) Universal blow puller for common rail injectors ALLOWED (NO PART No.) (NO PART No.) ALLOWED (NO PART No.) Puller for common-rail injectors on Mercedes Class A 8099-B BH 0 986 612 782 ALLOWED (NO PART No.4 .) ALLOWED (NO PART No.R01 . PEUGEOT 807.PULLERS FOR COMMON RAIL INJECTORS PROFESSIONAL DIESEL SERVICE TOOLS 8098 Special puller for common rail injectors on FIAT MAREA 8099-M Blow-puller for 2 BOSCH injectors on MERCEDES CLASS A equipped with common rail The puller can also be used for the fixing brack Extremely compacted puller NOTE: To avoid damages to the engine cover a wide plate should be placed between the screw and the engine Puller for CR Injectors ULISSE. CITROEN EVASION 320.5 8099-F 8099-U .R01 . R01 .7 Pliers for ring Common Rail injectors extraction 9899-CR 9764-CR 320.PULLERS FOR COMMON RAIL INJECTORS PROFESSIONAL DIESEL SERVICE TOOLS 8119 1/2 square drive socket wrench for DELPHI injectors (21 mm) on FORD TRANSIT and MONDEO YDT220 Alignment bracket for DELPHI common rail injectors YDT221 8121 Puller for CR Injectors Delphi R02601Z on REXTON 2.6 . 7 10019-KA LIGHT 10019-K 10019-SERIES PROFESSIONAL TOOLS FOR NOZZLE REPLACEMENT.R01 . ESSENTIAL TO PRESERVE THE ALIGNMENT PINS .www.marbed.com PROFESSIONAL DIESEL SERVICE TOOLS 10019-Series TURN TURN SAFE CO MM R ON AIL ING O TW R SP RS E NJ I NIT O CT U ANALOGIC 10019-KD 320. 10019-KA and 10019-KD preserve the integrity of all the components. The damage is not limited to the pins only: it can affect the body and the nozzle as well. two pins are introduced.R01 . the nozzle position is locked on the body and the nut rotation is free and secured. Screwing and unscrewing the nut. by pressing the nozzle on the body. At the right pressure.8 . ESSENTIAL TO PRESERVE THE ALIGNMENT PINS TURN TURN URN SAFE 320. To align the fuel hoses between the injector body and nozzle.PROFESSIONAL DIESEL SERVICE TOOLS 10019 SERIES PRESERVING THE ALIGNMENT PINS Common rail and two-spring injectors nozzles are designed with the top face completely flat. the nozzle tends to be dragged into rotation and the two pins can be truncated. 10019-TC is the option which can be installed only on 10019-KA. two-spring injectors and unit injectors.R01 . applied on unit injector (no adapter plate is requested). The clockwise rotation of the easy to use handle presses the nozzle on the injector body Instead of reading the applied force on the analogic angle graduation disk the display gives immediate and accurate indication of the applied force. 9 size plates provided 2 Nozzle size adapters provided T S 10019-TC SIMILAR TO 0 986 612 997 Digital torque calculator for 10019-KA. KA+TC=KD 320. 10019-KD is the modular solution obtained by adding 10019-TC (digital sensor) to the basic analogical tool 10019-KA. To accurately calculate the force applied to the nozzle on the injector body. 10019-TC is composed by a lcd display. with integrated commands and a loading cell.10019 SERIES PROFESSIONAL DIESEL SERVICE TOOLS NEW 09/ 201 0 10019-KD SIMILAR TO 0 986 613 400 + 0 986 612 997 Professional tool with digital torque to open/assemble the nozzle nut on common rail. The picture illustrates 10019-KD integrated with 10019-AR device.9 . Any existing 10019-K can be implemented adding 10019-AR. The sliding central body allows to hold unit injectors (no plate required) and any other injectors (by the proper plate). the angle displacement is the indirect indication of the applied force. 320. two-spring injectors and unit injectors. 9 size plates provided 2 Nozzle size adapters provided T S 10019-K 0 986 610 130 Professional tool with analogical torque to open/close the nozzle nut on common rail and two-spring injectors.PROFESSIONAL DIESEL SERVICE TOOLS NEW 09/ 201 0 10019 SERIES 10019-KA SIMILAR TO 0 986 613 400 Professional tool with analogical torque to open/assemble the nozzle nut on common rail. The clockwise rotation of the easy to use handle presses the nozzle on the injector body Rotate the graduated disk until the zero angle position corresponds to the arrow index.R01 . 10019-KA represents the primary device which can be implemented by adding 10019-AR or 10019-TC.10 . Continuing the handle rotation. 10019-KD and the indicator to be installed on the dynamometric wrench. The gauge is composed by two elements: the easy-to-read circular gauge to be installed on 10019-K. The clamping system requires to be installed on a standard workbench vice. and in intervals of 10 and 30. 10019-12 Clamping system for injectors. 10019-KA.PROFESSIONAL DIESEL SERVICE TOOLS 10019 SERIES 10019-AR NEW 09/ 201 0 Angular torque gauge for 10019-K. With this gauge. 320. Adjustable arm keeps angle scale stationary.R01 . For the common rail injectors. i Definition of torque + angle specification: If a torque + angle specification is given as 50 Nm + 70°. Diesel Injection Specialists can meet the demands of the new specifications: to tighten the nuts a specified number of degrees after initial torque is set. 360° angle scale-clearly marked in 2° increments. For component inspection and dismount or reassembly injectors. 10019-KD. then it is turned 70°. this device is very versatile using the same plates of 10019-KA. 10019-K. It can be implemented adding clamping adapters. the nut is first tightened to 50 Nm torque.11 . manufacturers are specifying both torque and angle settings. 12 .R01 .5 10019-8 9 22 10019-9 10 12 10019-11 11 HEUI WITH 2 BOBBINES 10019-22 12 HEUI ISUZU 10019-20 13 VOLKSWAGEN 10019-10H = Included = On request 320.PROFESSIONAL DIESEL SERVICE TOOLS 10019 SERIES ADAPTERS NOTES 1 10019 Series K KA KD 12 11 10019-1 2 14 10019-2 3 15 10019-3 4 16 10019-4 5 17 10019-5 6 19 10019-6 7 13 10019-7 8 14. 5 8101-8175 3 15 8101-15 27 8101-820 4 16 8101-16 5 17 8101-17 6 18 8101-18 7 19 8101-19 8 21 8101-21 9 22 8101-22 10 24 8101-24 11 27 8101-27 12 30 8101-30 13 32 8101-32 320. Double scale with graduation Nm/lbf.13 20 Toothed nut adapter a a a Teeth 27 18 code 8101-R 9785-C Dynamometrical wrench 20 .200 Nm 15 . With end fitting frontal connection.150 lbf. safety lock at the extremity.ft on handle below a window with a magnifying-glass effect that makes reading easier. For controlled bi-directional tightening. Adjustment obtained by rotating the ergonomically shaped nylon handgrip.PROFESSIONAL DIESEL SERVICE TOOLS Nozzle nut opening/closing Wrench Octagonal nut adapter a b a code a b code 1 13 8101-13 27 17 8101-8170 2 14 8101-14 27 17.Scale ± 3% tolerance of the scale set torque.ft 1 Nm . Supplied with test certificate as per DIN ISO 6789.R01 . Accessories 9785-C1 Insert for 1/2" square drive . and with 4 special fluid bottles Made in the usa 9698-VL3 9698-C Biodegradable fluid for diesel and electronic components in a 5 litres jug 9698-A Biodegradable fluid for diesel and electronic components in a 0.R01 .14 . timer and with an inox stainless basket to contain parts. The container is supplied with a heater.PROFESSIONAL DIESEL SERVICE TOOLS Ultrasonic Cleaner Transistorized ultrasonic cleaning machine with automatic setting.5 litres bottle 9896 Stainless steel plate for electro-nozzles 320. R01 .29 0 986 613 633 3 8160 .15 Bosch Injectors 0 445 120 007 0 445 120 041 and similar . Bosch Injectors 0 445 110 008 and similar 8160 . Bosch Injectors 0 445 110 002 and similar 30 mm hex. Denso Industrial and Siemens Injectors and similar 8160 .12 320.27 28 mm 5 12 faces 8160 .8160 .30 0 986 613 638 27 mm 4 12 faces Bosch Injectors on MAN 8160 .Solenoid wrenches PROFESSIONAL DIESEL SERVICE TOOLS CODE 1 FEATURES APPLICATION 27mm hex.27A 2 29 mm hex. Bosch Common Rail nozzleholders.PROFESSIONAL DIESEL SERVICE TOOLS Dismounting wrenches 10mm hexagonal socket hole 6. 8120-D Wrench with driver for dismounting the internal ring-nut of the Denso 320. 0 986 613 631 8120-12 8120-S Wrench with driver for dismounting the internal ring-nut of the C. 0 986 613 632 Wrench for mounting and dismounting internal ring-nut 12mm.16 . torx.R. Siemens injector on Ford and Peugeot.5 mm 10mm hexagonal socket hole 7.R01 . torx.5 mm 8120 0 986 613 630 8120-A 8120-10 Wrench for mounting and dismounting internal ring-nut 10mm. Bosch Common Rail nozzleholders. R01 .www.com 9700-CR 9700-CR .TOOLS FOR LAPPING COMMON-RAIL INJECTORS PROFESSIONAL DIESEL SERVICE TOOLS Set of tools for lapping the ball seat of common-rail injectors.17 1 Hexagonal socket 1 Hexagonal socket 1 Lapping paste 1 Lapping paste 2 Pin 1 Pin guide 9700-CR .marbed. 8120 8120-A 9015 9018 8162 8163 320. 5 mm Lapping paste. chrome green Pin with the appropriate cone to lap the ball seat of common-rail injectors Pin guide to be mounted on the common-rail injectors 8120 0 986 613 630 8120-A 9015 9018 8162 8163 320.TOOLS FOR LAPPING COMMON-RAIL INJECTORS PROFESSIONAL DIESEL SERVICE TOOLS 10mm hexagonal socket hole 6.5 mm 10mm hexagonal socket hole 7.R01 .9700-CR .18 . grain 600 Lapping paste. 19 Use one of the 10 hard steel balls 10 Kits Each kit includes also a replacement ball Press the button for 5 sec DONE! .com 8210 0 Ball reseating tool for BOSCH common-rail injectors 10 hard steel balls Connect compressed air (6-10 bar) Insert the body of ball seat 8210-R 320.marbed.R01 .www. R01 .www.858 pieces Set of calibrating spare parts for Bosch common rail injectors 12 articles .com 8210-RTX 8210-RTX SET OF TOOLS AND SPARE PARTS FOR BOSCH CR INJECTORS PROFESSIONAL DIESEL SERVICE TOOLS Set of tools and calibrating spare parts for Bosch common rail injectors 17 articles .850 pieces 8210-RTX 8210-RX 320.marbed.20 . high precision tweezers reccomended for the positioning of spare parts on common rail injectors Sliding inserter for ring and seal of common rail injectors Inserter for the body of ball seat of common rail injectors Ring and seal extractor of common rail injectors 320.R01 . stainless steel.21 8210-T2 8210-T3 8210-T4 8210-T5 .8210-RTX SET OF TOOLS AND SPARE PARTS FOR BOSCH CR INJECTORS PROFESSIONAL DIESEL SERVICE TOOLS Tools A Vacum pick and place pen tool reccomended for the handling of the ball on common rail injectors it includes 2 anti-magnetic adapters (A and B) 8210-T1 B Anti-magnetic. 54 1.46 1.10 8210-R34 O 0.50 1.02 1.49 8.44 1.64 1.40 1.22 1.58 1.19 1.38 1.43 8.26 1.25 8210-R13 L 8.38 1.17 1.24 1.23 1.14 1.52 1.44 1.45 8.36 1.06 1.PROFESSIONAL DIESEL SERVICE TOOLS 8210-RTX SET OF TOOLS AND SPARE PARTS FOR BOSCH CR INJECTORS Adjusting spare parts (5 pcs each measure) 8210-R06 / 8210--R07 8210-R05 8210-R04 8210-R41 8210-R53 8210-R29 8210-R28 8210-R34 8210-R35 8210-R13 8210-R14 1 2 3 4 5 6 7 8 9 10 11 12 A 1.64 1.56 1.20 1.47 8.58 1.66 I 1.42 8210-R04 8210-R05 8210-R06 8210-R07 H 1.30 1.22 1.52 1.66 C 1.03 1.27 1.24 1.48 1.52 1.24 1.99 1.01 1.26 1.28 1.50 1.41 8.50 1.00 1.56 1.22 .56 1.20 1.26 1.48 1.42 8.48 8.38 1.44 8.30 1.46 1.46 1.48 1.60 1.19 1.18 1.00 1.62 1.28 1.66 G 1.08 1.21 1.20 1.23 1.20 1.42 8.54 1.34 1.64 1.54 1.51 8210-R28 M 8.32 1.40 8.08 1.25 1.40 1.24 1.05 1.62 1.36 1.60 1.36 1.40 1.36 1.51 8210-R29 N 0.60 1.32 1.10 8210-R35 P 1.20 1.30 1.48 8.52 1.06 1.42 D 1.62 1.34 1.38 1.42 B 1.46 1.02 1.15 1.34 1.48 1.21 1.44 8.04 1.32 1.62 1.45 8.44 1.42 F 1.30 1.24 1.66 E 1.09 1.32 1.47 8.26 1.40 1.56 1.99 1.50 8.41 8.09 1.54 1.28 1.34 1.46 8.49 8.50 1.46 8.07 1.64 1.24 1.50 8.58 1.58 1.16 1.04 1.43 8.22 1.22 1.20 1.30 8210-R41 320.07 1.28 1.40 8.28 1.05 1.R01 .03 1.44 1.22 1.26 1.29 1.22 1.60 1.01 1. 23 Recommended microscope X20. 8210-R Each set includes: .inlet cap Set of 15 measures of copper gaskets packed in 30 each Recommended tool to manufacture a circle of perfect sealing on the ball seat 320.return cap .PROFESSIONAL DIESEL SERVICE TOOLS 8210-RTX SET OF TOOLS AND SPARE PARTS FOR BOSCH CR INJECTORS Other spare parts (not included in 8210-RTX and 8210-RX) 8210-R31 Plastic connection for the return 8210-R32 Metallic spring to retain 8210-R31 F00V C22 003 8210-R26 Solenoid O-Ring 8210-R27 Inlet gasket 8210-R22 Metallic ball 8210-R38 Ceramic ball 8210-R21 Gasket ring 8210-R20 Steel ring 10 Sets of repairing spare parts.nozzle cap .8210-R26 Solenoid o-ring .R01 .8210-R21 Gasket ring .8210-R22 metallic ball .8210-R27 Inlet gasket .8210-R20 Steel ring . with lights 9795 8210 8210-M . 24 .PROFESSIONAL DIESEL SERVICE TOOLS Motoring Reamer 9000-D 9000-C 9000-B Ø 19 8043 Ø 17 Flat milling cutter for nozzle holders seats on MERCEDES Ø 17 8043-A Ø 17 Flat milling cutter for nozzle holders seats on MERCEDES Ø 19 Ø 15 Ø 17 8043-B Flat milling cutter for nozzle holders seats on MERCEDES SPRINTER Ø 21 8044 Ø 17 Coned milling cutter for nozzle holders seats on FIAT DUCATO DAILY Ø 21 8045 Ø 17 Flat milling cutter with large guide for nozzle holders seats on FORD TRANSIT and FIAT CROMA INCLUDED NOT INCLUDED 320.R01 . 5 2 10 9795 .5 1.5 4 9795 .5 3 320.5 2 5 9795 .01 15 7 .15 14.5 8 9795 .09 15.6 7.14 14.R01 .4 2 12 9795 .25 .04 15 7.03 15 7.4 7.with notches 2 2 9795 .05 15 7.5 3 7 9795 .9795 .7 9 9795 .5 1 3 9795 .13 13.3 1.10 16 7.Copper washers PROFESSIONAL DIESEL SERVICE TOOLS 9795 Plastic box 15 compartments containing copper washers for injectors 30 pieces each type CODE (30 pcs.5 2.08 16 7.3 15 9795 .06 15 7.5 2 11 9795 .85 7.11 16.9 13 9795 .5 1.07 16 7.6 7.5 1.5 6 9795 .12 20 9.02 15 7.5 7.5 1. each) 1 9795 .4 0.4 14 9795 . .R01 .65 9795 . each) 9795 .5 9795 .7 .7 .Copper washers other sizes PROFESSIONAL DIESEL SERVICE TOOLS 9795 Copper washers sizes for injectors 30 pieces each type 16/17/18/19 CODE (30 pcs..18 15 7..16 14 7.2 1.. Copper washer remover 9795-T 320.with 6 notches 2. ..with 4 notches 1.with 3 notches 1..5 9795 ..7 .19 15 7. .26 .. ..5 9795 .17 15 7. 4 .Italy This catalog is. replace the previous edition that is now obsolete. . drawings. All specifications.www.10.r.26.Fax +39 02. +39 02.com MARBED BOOK 2011 ©2011 MARBED S. shown in this technical catalog. dimensions.Piazza Novelli. The illustrations are not binding..l.20129 Milano . The data and information. so the reproduction in part or in full of photos. PROFESSIONAL DIESEL SERVICE TOOLS www.marbed. is prohibited.84 .49.com MARBED Srl . protected by copyright.67 e-mail info@marbed. weights in this catalog are subject to change without notice.marbed.71. etc.70. Original part numbers listed in this catalog are given for reference. to all intents.com .Italy Tel.