How to remove a seized injector - VIBRO SYSTEM

How to remove a seized injector? Sometimes even - how to tear out a seized injection ?! Such questions are more and more often asked by mechanics repairing diesel cars.

This is not easy. That is the simplest answer. Are you sure?

In a nutshell, the problem of a seized injection comes from the water that gets over the cylinder head cover and rests in all its cavities, including the injector seats. Water comes from the rain and flows down the pit, from frequent engine washing or from damaged washer and radiator hoses. Long-term exposure to water causes corrosion of the steel housing of the injector and rust "bites" into the soft aluminum head. Rust deposits wedge the injection and, after unscrewing the fastening nut, it cannot be pulled out - although it was easily inserted there.

There are several effective injector extraction systems and technologies. Pichler stands out among them undoubtedly, who is a master in pulling out extremely tight injections. On the other hand, as much as 75% of the injectors, which cannot be dismantled with ordinary tools, are medium and strong seized. In this case, ROOKS has the appropriate technology. So what does ROOKS technology look like and how does it work?

It is the VIBRO SYSTEM technology based on high frequency pulsating forces. Ripple force, i.e. impact force, is up to three times more effective at breaking joints and corrosion gangrene than a constant force or a linear increasing force. Rust quickly wears out and the corrosion centers are sheared, and the injector is removed from its seat in the cylinder head.

Photo 1: VIBRO SYSTEM ROOKS in action; pneumatic hammer OK-04.0100

The heart of the ROOKS VIBRO SYSTEM tools is a very strong pneumatic hammer with a quick coupler and an inertia puller. The hammer itself has an impact energy of almost 7 J. The hammer together with a puller allows to obtain a pulling force comparable to a hydraulic press of 10 or even 12 tons! The hammer and puller are supplemented with adapters for various injectors available on the market. The full program consists of only 10 tools! This is a huge advantage of the ROOKS system because it means low cost in relation to the solutions of the competition.

Photo 2: ROOKS OK-05.0010 slide hammer

The entire program of VIBRO SYSTEM tools is presented in table 1:

TAB.1

Photo 3: Bosch OK-05.0011 two-point adapter; ball joint OK-05.0017; Simens M27 adapter OK-05.0013

The principle of operation of the VIBRO SYSTEM is simple. Unscrew the injector coil, remove the valve and screw the appropriate adapter into the injector. In the case of the Bosch injector, a two-point adapter is used, which distributes the force on the internal and external threads, this is the optimal solution. Then connect the slide puller to the adapter (5/8 ”thread). Sometimes a ball joint is helpful, which allows working at an angle of up to 30 °, and this is sometimes necessary due to lack of space or the position of the injector. The joint is then attached to the adapter and the puller to the joint. Attach the impact socket in the puller, which is connected to the pneumatic hammer. The hammer quick coupler enables the spigot to work freely with a long working stroke of the pneumatic hammer. It is very important to properly tighten all system components and tighten the locknuts. As the VIBRO SYSTEM is an impact tool, loose parts can be damaged. If the nuts are not countered, the threads in the puller and adapters will be damaged. The same applies to tightening and countering the pneumatic hammer quick coupler to the impact socket.

The technical data of the VIBRO SYSTEM are as follows: impact energy 6.9 J; 2200 cycles per minute and a very long working stroke - up to 98 mm. The pneumatic hammer has a quick coupler which, in addition to the easy mounting of the spigot, allows it to work freely and does not strain at maximum deflection (which is often the case when mounting spigots with a spring). Additionally, the hammer must be narrow and long enough to fit along the arm of the inertia puller and work perfectly along its axis. All adapters are made of thermally hardened high-alloy tool steel. The inertial puller has a 50 cm long arm and a weight of 2 kg. The system is powered by a pneumatic installation with a pressure of 6.3 BAR.