Technical data

Repair instructions

Copper sleeve for injectors

Special tools, 6(x) series: 9812546, 9996400,

9996402, 9996419, 9996421, 9996643, 9996650,

9996651, 9996657, 9996867, 9998070

7(x) series: 9812546, 9996400, 9996402, 9996419,

9996420, 9996643, 9996657, 9996861, 9996867

The copper sleeve can be changed with the cylinder

head either installed or detached.

The seat for the copper sleeve must never be cleaned

up with a cutting tool, with the cylinder head still in-

stalled on the engine.

The seat may be cleaned with a nylon brush with the

cylinder head still installed on the engine.

Measures to be taken with the cylinder

head installed

Drain the coolant (fresh water system).

Clean round the injectors. Remove the fuel leakage

pipe and fuel supply pipes. Plug the connections.

Remove the valve covers.

NOTE! Do not undo the individual pipes. Remove all

the pipes as a package, i.e. all the pipes which are

clamped together.

IMPORTANT! No fuel pipe must be bent or

deformed, since cracks may occur which

would lead to failure.

Turn the injector with a 15 mm open-ended spanner,

and pull it upwards at the same time. If the injector is

stuck, it must be removed with puller no. 9996643.

Pull out the steel ring above the copper sleeve. Use

extractor no. 9996419 together with underlay 9996867.

NOTE! To avoid damaging the extractor spindle during

extraction, the spindle must be kept stationary and

tightening must be done with the nut.

It is the nut which must do the work.

The tool can be supplemented by impact hammer

9996400.

Pull the copper sleeve out with extractor no. 9996657.

First press the extractor sleeve to the base of the

copper sleeve. Hold the extractor still and turn the

spindle anti-clockwise until the tool grasps the copper

sleeve firmly.

Remove the injector retaining yoke, where the copper

sleeve is to be replaced, and the dust cover over the

injector.