Pneumatic reverse hammer for removing injectors

Drawing hammer for removing injectors

You shouldn’t get down to business without a drawing. It is necessary to imagine the design, structure of the pneumatic hammer, the number of components of the future tool, the sequence of their connection into a single whole.

Before designing, decide on the dimensions. usually a length of 50 cm is enough to crawl under the hood and remove the burned-out nozzle. The drawing can be found and downloaded on the Internet. Having assembled the necessary components, if you know the principle of operation, you will independently make a drawing for your exclusive reverse hammer and remove the injectors without dismantling the cylinder head.

DIY pneumatic diesel injector puller

The injectors are located in a hard-to-reach place. the well of the cylinder head (cylinder head). From exposure to dirt, moisture, these elements rust and adhere firmly to the seat. Screw and hydraulic pullers cope with dismantling, however, the parts immediately fall in two, becoming unrepairable.

Pneumatic Diesel Injector Puller

How to make a reverse hammer for removing injectors with your own hands

Before designing, decide on the dimensions. usually a length of 50 cm is enough to crawl under the hood and remove the burned-out nozzle. The drawing can be found and downloaded on the Internet.

Diesel engine injectors need to be replaced and repaired. It is not difficult to restore the parts, the question may arise with how to dismantle them. Auto repair shops use a special tool, the price of which starts from 30 thousand rubles. Therefore, to remove the nozzles with their own hands, drivers often make a reverse hammer. To do this, you need to have locksmith and turning skills, experience with a welding machine, cutting tools.

Materials and tools

From power tools, you will need a powerful autocompressor with a capacity of 250-300 l / min, an angle grinder, and a pneumatic chisel. From the latter, already at the preparatory stage, remove the boot, retaining ring and bushing with a spring: they are no longer needed.

To make a reverse hammer for removing injectors with your own hands, you will also need:

hose connection;
hacksaw for metal;
gas and wrenches;
calipers.

Don’t forget the air hoses for the compressor.

Manufacturing instruction

You have already removed unnecessary parts from the pneumatic chisel.

Then you can make a reverse hammer for nozzles with your own hands in steps:

Clamp the chisel in a vice, unscrew the cylinder from the body.
Remove the piston from the removed part, followed by the air valve.
Outside the cylinder from the front cut, cut the thread for the plug.
Unscrew the sleeve for the fitting from the chisel handle, cut the body into 2 parts.
Measure all the details of the inside of the case: threads, place of the air hole, other parameters.
Turn another cylindrical body on a lathe. It is necessary that its inner surface matches the sawn part.
Next, on the machine, make a shank on the outside of the rear wall. a rod of 5 cm and a diameter of 1.5 cm.
Carve out a plug, the internal thread of which matches the external thread on the cylinder.
Tempered body and end cap for strength.
Weld a sleeve over the air valve.
Place the tail cut from the chisel for the air tool into the end of the cylinder.
Install the piston inside the cylinder.
Screw the wide part of the cylinder into the new housing.
In the other part, insert the already prepared chisel shank, tighten the plug (secure the part from unscrewing with a fixing bolt).
Screw the fitting over the air hole through the adapter, fix the air duct from the compressor to it.

The reverse hammer for do-it-yourself nozzles is ready to go. The tool will also come in handy for bearing removal.

Drawing hammer for removing injectors

Before designing, decide on the dimensions. usually a length of 50 cm is enough to crawl under the hood and remove the burned-out nozzle. The drawing can be found and downloaded on the Internet.

Materials and tools

From power tools, you will need a powerful autocompressor with a capacity of 250-300 l / min, an angle grinder, and a pneumatic chisel. From the latter, already at the preparatory stage, remove the boot, retaining ring and bushing with a spring: they are no longer needed.

Prepare metal blanks, from which the body and plugs of a pneumatic hammer are usually turned on a lathe.

Blanks for the manufacture of a reverse hammer for removing injectors

To make a reverse hammer for removing injectors with your own hands, you will also need:

hose connection;
hacksaw for metal;
gas and wrenches;
calipers.

Don’t forget the air hoses for the compressor.

DIY pneumatic diesel injector puller

If you want to dismantle the nozzles with your own hands intact, build a pneumatic reverse hammer.

Do-it-yourself reverse hammer for removing nozzles. drawing, list of materials, manufacturing instructions

Having assembled the necessary components, if you know the principle of operation, you will independently make a drawing for your exclusive reverse hammer and remove the injectors without dismantling the cylinder head.

Diesel engine injectors need to be replaced and repaired. It is not difficult to restore the parts, the question may arise with how to dismantle them. Auto repair shops use a special tool, the price of which starts from 30 thousand rubles. Therefore, to remove the nozzles with their own hands, drivers often make a reverse hammer. To do this, you need to have locksmith and turning skills, experience with a welding machine, cutting tools.

Manufacturing instruction

You have already removed unnecessary parts from the pneumatic chisel. Then you can make a reverse hammer for nozzles with your own hands in steps:

Clamp the chisel in a vice, unscrew the cylinder from the body.
Remove the piston from the removed part, followed by the air valve.
Outside the cylinder from the front cut, cut the thread for the plug.
Unscrew the sleeve for the fitting from the chisel handle, cut the body into 2 parts.
Measure all the details of the inside of the case: threads, place of the air hole, other parameters.
Turn another cylindrical body on a lathe. It is necessary that its inner surface matches the sawn part.
Next, on the machine, make a shank on the outside of the rear wall. a rod of 5 cm and a diameter of 1.5 cm.
Carve out a plug, the internal thread of which matches the external thread on the cylinder.
Tempered body and end cap for strength.
Weld a sleeve over the air valve.
Place the tail cut from the chisel for the air tool into the end of the cylinder.
Install the piston inside the cylinder.
Screw the wide part of the cylinder into the new housing.
In the other part, insert the already prepared chisel shank, tighten the plug (secure the part from unscrewing with a fixing bolt).
Screw the fitting over the air hole through the adapter, fix the air duct from the compressor to it.

The reverse hammer for do-it-yourself nozzles is ready to go. The tool will also come in handy for bearing removal.

DIY reverse hammer: mechanical and pneumatic

The impact impulse of a simple hammer is directed into the struck surface, as a result of which it deforms. In the reverse hammer, the direction of the impulse is opposite, due to which it becomes possible to eliminate the deformation. The device is widely used in the body repair of damaged cars and, in skilled hands, removes even deep dents. A return hammer will also help when removing bearings in hard-to-reach places. The pneumatic version of the device is used to extract burnt injectors of diesel engines. The article will tell you how to make a do-it-yourself reverse hammer.

The most common mechanical and pneumatic devices are:

Mechanical. The structure consists of a metal rod about 50 cm long and 1.5-2 cm in diameter, which is equipped with a handle with a metal stop. A freely moving cylindrical metal weight is put on the rod. The free end of the rod is attached to the deformation point or to the bearing using various attachments or welding. The kettlebell moves forward along the rod by hand, then is sent back with force. When the weight hits the metal stop of the handle, the device moves away from the surface, pulling out the dent or removing the bearing. It is not difficult to make a reverse hammer suitable for body repair on your own.
Pneumatic. The device is similar to a pneumatic jackhammer, in which a metal piston hits the shank of the lance at a frequency of several thousand beats per minute. In the reverse hammer, the piston strikes the wall of the device, as a result of which the hammer receives an impulse of movement directed towards the impact. The resulting force is sufficient to extract 90% of burnt-out injectors of diesel engines during repairs. The return hammer is also suitable for removing bearings, especially in awkward, hard-to-reach places. An industrial product is convenient to operate, but expensive. The cost of the reverse hammer described in the article is much lower. However, its manufacture requires experience in locksmith and turning work, drawing skills, which may not be within the power of a beginner.

Mechanical reverse hammer

two used rear car racks VAZ 2108;
two pieces of metal pipes 12 cm long;
old side handle from any power tool;
metal washer 60 mm with a hole diameter of 22 mm;
lead for weighting;
electric welding machine;
gas burner (for lead melting);
angle grinder or hacksaw.

The construction reservoir is cut in a circle from the side of the rod at a distance of 2 cm from the edge.

A hammer knocks out the guide sleeve of the stem.

Two rods are connected by threadless ends, welded. The junction is cleaned and polished. The resulting rod is about 60 cm long with threads at both ends.

On one side, a 60 mm washer is put on the rod and welded. The distance from the edge to the attachment point is selected depending on the length of the handle.

Sections of pipes (one is slightly thicker than the rod, the second can be cut off from the rack reservoir) are inserted into each other and aligned. the walls of the pipes should not touch each other. On one side, a washer of a suitable size is welded onto the pipe cuts.

Pieces of lead are placed in the space between the pipe sections. The part is heated by a torch until the lead is melted.

After the lead has solidified, the impact weight is ready. For ease of use, you can put on the support of the compression buffers of the racks, which look like metal covers with a central hole.

A safety washer is fastened to the end of the hammer opposite to the handle with nuts, which prevents the weight from sliding off the rod.

Pneumatic Reverse Hammer

pneumatic chisel. Compared to a pneumatic hammer, it has a smaller size. the converted device will be convenient to work in the engine compartment of a car;
metal blanks for the manufacture of the device body and plugs on a lathe;
metal hose fitting;
angle grinder, hacksaw for metal, gas and wrenches, measuring tools;
compressor with a capacity of 250-300 liters of air per minute, air hoses.
The rubber boot, retaining ring, bushing and spring are removed from the cylinder of the pneumatic chisel. these parts after alteration are no longer needed.
The body with the handle is clamped in a vice. Using a gas wrench, the cylinder is unscrewed from the body. You will have to make significant efforts. the thread of the cylinder in many models is made at a certain angle.
The impact piston and air valve are removed from the removed cylinder. A thread 3-4 cm long is cut on the outer wall of the cylinder from the front cut. a plug will be screwed onto it.
A sleeve for a fitting with a mesh is unscrewed from the chisel handle to prevent debris from getting into the device.
The air chisel body is cut in two.
The details of the inner surface of the case are carefully measured: length, angle and pitch of the thread, location of the air hole, shape of the back wall, etc.
A detailed drawing is produced.
According to the drawing, a new cylindrical body is made on a lathe, the inner profile of which, as well as the location of the air hole, corresponds to the sawn part. When turning on the machine, it is desirable that the sawn body is near. additional measurements may be needed. Outside the rear wall, the tail part is turned by a turning method. a rod 5-7 cm long and 1.5-1.6 cm in diameter with a thread. Devices for fixing and removing injectors will be attached to the shank. A plug is separately machined, the internal thread of which corresponds to the one previously cut on the cylinder. This stage of manufacturing a hammer is the most critical. The performance of the product and the safety of working with it will depend on the accuracy of manufacturing. Therefore, turning must be carried out by a qualified technician.
To increase strength, the manufactured body and plug are hardened.
A metal bushing is welded over the air hole outside the housing, the internal thread of which corresponds to the thread of the bushing with a protective mesh.
A tail is cut off from a metal chisel for a pneumatic tool. After placing the cut part at the end of the cylinder, it should be flush with its cut. The bit shank is made of carbide material and can withstand piston impacts.
A piston is placed inside the cylinder.
The wide part of the cylinder with the air valve installed on it is screwed into the new housing. To obtain the required torque when tightening, it is advisable to make grooves for a wrench on the cylinder body.
The cut shank of the chisel is inserted into the upper part of the cylinder and the plug is screwed on. To prevent it from being unscrewed during operation, a 6 mm hole is drilled in the housing, a thread is cut and a fixing bolt is tightened.
An adapter with a protective mesh and a fitting for an air hose are screwed into the bushing above the air hole.
An air hose is attached to the fitting. Pneumatic reversing hammer ready to work.

We hope that you have learned a lot of useful things and with the help of step-by-step instructions you can make a reverse hammer yourself.

Complete set of branded vibration puller of injectors

A factory made inertial puller kit may include:

an extractor unit that can withstand operation at different frequencies and amplitudes;
a locking rod of the vibrating rod for fixing;
stepped thrust rings, usually one or two;
a bearing ring that improves sliding and smooth pulling out of the nozzle;
power nut made of high strength steel to prevent rapid thread wear;
a package of spring washers eliminating rigid fixation that can cause damage to the head and nozzles;
protective ring for increased safety when working with the puller.

TDI Diesel Injector Slide Hammer Puller Tool Used to Remove Stuck Injectors

To pull out the nozzle, it must be exposed to vibration. The puller does not have the ability to create it on its own, therefore, when dismantling the injectors, you need to connect a Vibropac vibrator, often used to remove jammed spark plugs.

Diesel injector puller pneumatic

The pneumatic diesel injector puller uses the reverse hammer principle. The injector puller is very convenient when working in a confined engine compartment. Suitable for a large number of Bosch, Denso, Delphi, Siemens injectors.

Examples of connections of injectors with an injector puller:

Thanks to the effort developed by the blow of the pneumatic hammer, in 90% of cases it is possible to dismantle heavily sour, jammed, rusted diesel injectors without removing the cylinder head, which in turn saves a lot of time, effort, nerves and money during repairs.

The set of the pneumatic puller includes adapters for the main types of nozzles:

Removing injectors with pneumatic hammer!

Additionally, it is possible to purchase adapters for injectors that are not included in the main delivery set (pay attention, the photos show adapters without finishing, adapters will be on sale after processing and painting):

The company Autoscanners is the official distributor of the products of the company ODA Service

Diesel injector puller pneumatic

Diesel injector puller, pneumatic ODA-3203 Review

Pneumatic fuel injector pullers ODA-3204 and ODA-3203

During the operation of the car, it becomes necessary to remove the injectors for replacement or diagnostics. At this moment, the car owner may be in for trouble in the form of a stuck injector. The reasons for this can be both overheating of the engine, and simply oxidation of the contact point, caused by the influence of an aggressive environment. Excessive force will damage the injector. Very often it moves slightly from its place, and then wedges, making it impossible to move in any direction. To solve problems, a special puller comes to the rescue, designed to dismantle stuck injectors.

Homemade dismantling methods

When disassembling with your own hands, it is important to remember the risk of damage to the cylinder head. If excessive force is applied together with the nozzle, part of the seat may come off. After this, it is impossible to do without costly repairs, therefore it is forbidden to hollow out the nozzle using improvised means, for example, a perforator or a jackhammer.

A self-made nozzle remover allows the nozzle to be removed without the need for a Vibropac vibrator. In this case, the chance of damage to the cylinder head and the extraction time increase. The service life of a homemade device is small, so a torn thread during dismantling is not uncommon.

Hydraulic puller

In some cars, for example, Mercedes Vito, Renault Master, Toyota Hiace, the use of an inertial puller is difficult. This is due to the lack of space for its placement. In this case, a hydraulic nozzle puller comes to the rescue, capable of dismantling in the most inaccessible places.

When dismantling fuel injectors with this device, a hydraulic hose must be connected, therefore, in the absence of equipment that provides pressure, it is not advisable to purchase a puller. For the operation, it is recommended to contact the service center.

Instructions for removing stuck injectors

To dismantle the injectors using a proprietary puller, it is recommended to adhere to the following sequence:

Eliminate all impurities by blowing with compressed air;
Pour penetrating grease, for example, WD-40, into the gap between the nozzle and the seat;
Install an inertial puller over the stuck nozzle;
The return fuel drain connection must pass through the positioning slot;
Using a torque wrench, screw the spindle onto the threaded part of the injector. It is necessary to tighten with the nominal torque specified in the technical description of the vehicle. Most cars have a force of 20 Newtons per meter;
Put on the washer with the turned side down;
Place the second washer on top. Its spherical side should look down. To increase the smoothness of dismantling and extend the service life, it is recommended to lubricate the device with oil;
Put on the package of spring washers. included with a proprietary nozzle puller;
Tighten the nut by hand. When the effort becomes insufficient, a 36 key is required. Tighten until a little effort appears.

Further work is associated with the use of a Vibropac vibrator. In its absence, craftsmen recommend tapping with a hammer. This method will work if the nozzle is slightly sticking. In this case, the risk of damaging the cylinder head cover is extremely high, so this method is not advisable to use. If Vibropac is available, further instructions are given below:

Remove the spark plug removal tool;
Shut off the air supply as much as possible;
Put on the impact pin;
Mark the key on the nut;
Press the Vibropack pedal;
At a certain moment, under the influence of vibration, the nut begins to tighten. This indicates that the removal of the injectors is successful. In this case, excessive effort should not be applied to the key;
It is necessary to tighten the nut in combination with the action of vibration;
At a certain moment, the nozzle will be released. It is necessary to remove the key and remove it together with the puller.

A feature of working with a self-made stripper is a preliminary long-term soaking with a penetrating lubricant or a corrosion inhibitor. In case of insufficient preliminary preparation, there is a risk of damaging the thread of the injector as soon as the key makes the first turn. After that, its removal becomes much more difficult.

Using a puller saves time, since there is no need to dismantle the cylinder head cover. Accuracy in work will keep the seat intact. It is enough to clean it, and you can install a new nozzle.

Allows to dismantle injectors of Mercedes CDI diesel engines without having to remove the block head

Suitable for engines OM611, OM612, OM613

Let’s consider the operation of the Licota ATA-0476 diesel injector remover and ATA-1402 diesel injector seat cleaning attachments using the example of the JEEP Grand Cherokee

Having disconnected all the connectors, we easily remove the nozzle using a puller with a reverse hammer

The photo shows how to install the puller

The injector remains intact after dismantling

To process the injector seat, we use the Licota ATA-1402 set

Nozzle seat (before processing)

We select a countersink suitable for the diameter of the well

Mercedes w211 injector removing with new pneumatic slide hammer

We clean the nozzle seat with a countersink

At the same time we blow air through the hole for the glow plug so that the chips do not fly into the cylinder

Nozzle seat (after processing)

With the help of these two sets, you can easily and professionally carry out work on the installation and dismantling of diesel fuel injectors.

Sources:

http://avtoshark.com/article/ratings/accessories/obratnyj-molotok-dlya-snyatiya-forsunok/
http://tehnopanorama.ru/instrumenty/obratniy-molotok-svoimi-rukami.html
http://jimnysuzuki.ru/avtomobili/obratnyj-molotok-dlja-forsunok.html