Bosch BTG 5120 User manual

BTG 5120
HDEV5/6 Tool Kit
en-gb Original Instructions
de Originalbetriebsanleitung
cs Originální návod k použití
da Originale brugsanvisninger
el Πρωτότυπο οδηγιών χρήσης
es-es Instrucciones originales
fi Alkuperäiset ohjeet
fr-fr Instructions d'origine
hr Izvorne upute
hu Eredeti útmutató
it Istruzioni originali
ja 元の手順
ko 원래 지침
nl Originele instructies
no Opprinnelige instruksjoner
pt-pt Instruções originais
ro Instrucţiuni originale
ru Инструкции на языке оригинала
sl Originalna navodila za uporabo
sv Originalinstruktioner
tr Orijinal Talimatlar
zh-cn 原始说明

Table of Languages
English (Great Britain) ....................................................................................................... 4
Deutsch ............................................................................................................................. 19
Čeština .............................................................................................................................. 34
Dansk ................................................................................................................................ 49
Ελληνικά ........................................................................................................................... 64
Español (España) .............................................................................................................. 79
Suomi ................................................................................................................................ 94
Français (France) ........................................................................................................... 108
Hrvatski .......................................................................................................................... 123
Magyar ............................................................................................................................ 138
Italiano ............................................................................................................................ 152
日本語 .............................................................................................................................. 168
한국어 .............................................................................................................................. 182
Nederlands ..................................................................................................................... 196
Norsk .............................................................................................................................. 212
Português (Portugal) ...................................................................................................... 227
Românǎ ........................................................................................................................... 242
Русский .......................................................................................................................... 257
Slovenščina ..................................................................................................................... 273
Svenska ........................................................................................................................... 287
Türkçe ............................................................................................................................. 301
简体中文 ........................................................................................................................... 315
Table of Languages | 3 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

Table of Contents – English (Great Britain)
1 General Information ....................................................................................................... 5
2 General Safety Information ........................................................................................... 9
3 Operating Instructions ................................................................................................. 10
3.1 Replace the combustion chamber sealing ring and the decoupling element .......................................... 10
3.1.1 Removing the combustion chamber sealing ring .................................................................................. 10
3.1.2 Replacing the decoupling element with wire ring on the HDEV6 ........................................................ 11
3.1.3 Installing the new combustion chamber sealing ring ............................................................................ 13
3.2 Replacing the O-ring with the support disk on the hydraulic interface .................................................. 15
3.3 Using the hold-down element ................................................................................................................... 16
3.3.1 Replacing the hold-down element ......................................................................................................... 16
3.4 Installing the HDEV5/6 in the vehicle ....................................................................................................... 16
4 Inspection and Maintenance ........................................................................................ 17
en-gb | 4 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

1 General Information
Product name: BTG 5120
Product description: HDEV5/6 tool kit
Product type: Tool
Product number: 0 986 615 637
Weight: 0.75 kg
Intended use:
Replace the combustion chamber sealing ring on
the Bosch high-pressure fuel injection valve (HDEV).
Replace the O-ring with support disk on the HDEV6.
Replace the decoupling element.
Terms of use:
Only for qualified workshop personnel.
Use only for work approved by Robert Bosch GmbH.
Use only original parts of the HDEV5/6 tool kit and
spare parts kit to service Bosch high-pressure fuel
injection valves (HDEV).
Use only in enclosed workshops with a roof and
store the tool in an environment free of dirt,
corrosion, and condensation.
Use and store only in environments with a relative
air humidity up to 70%.
Use only with sufficient light and good visibility.
Wear suitable protective gloves that are clean and
free of lint.
Prevent foreign particles or liquids from getting
into the HDEV by all means when carrying out
service work.
When sensitive locations are under stress (e.g.
injector tip, electrical plug connection, hydraulic
interface, etc.), stop using the HDEV.
Do not install damaged or soiled HDEV or spare
parts.
Figure 1: HDEV5/6 tool kit
en-gb | 5 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

Included in delivery:1
Item
number: Product name: Part number: Quantity:
1 Case SP04002160 1
2 Pliers HDEV5/6 SP04001774 1
3 Hook for wire ring (HDEV6) SP04002136 1
4 Calibration pin (HDEV5) SP04002133 1
5Assembly sleeve for O-ring (HDEV6) SP04002689 1
6 Calibration pin (HDEV6) SP04001751 1
7 Calibration sleeve (HDEV5) SP04002132 1
8 Calibration sleeve (HDEV6) SP04001750 1
9Mounting taper (HDEV6) SP04002686 2
10 Mounting taper (HDEV5) SP04002688 2
11 Assembly sleeve for wire ring (HDEV6) SP04002690 1
12 Original instructions (USB Stick) SP04006245 1
13 Case inlay (HDEV5/6) SP04002162 1
1) When ordering spare parts, see table "Available spare parts of the HDEV5/6 tool kit".
en-gb | 6 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

Available spare parts of the HDEV5/6 tool kit:
Product name: Spare part number: Quantity:
Pliers HDEV5/6 SP04001774 1
Mounting taper (HDEV6) SP04002686 1
Mounting taper (HDEV5) SP04002688 1
Calibration set (HDEV5):
Calibration pin
Calibration sleeve
SP04006181 1
Calibration set (HDEV6)
Calibration pin
Calibration sleeve
SP04006180 1
Wire and O-ring set (HDEV6)
Assembly sleeve for O-ring
Assembly sleeve for wire ring
Hook for wire ring
SP04006182 1
en-gb | 7 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

Necessary spare part kits1 to service a high-pressure injection valve :
Product name: Quantity:
Spare part kit HDEV5 1
Spare part kit HDEV6 1
Robert Bosch hold-down element if required
1) The configuration of the spare part kits varies depending on the vehicle/manufacturer. For more information
on installation and removal, and spare parts kits, refer to the ESI[tronic].
Positions of the combustion chamber sealing ring on the valve tip1:
HDEV5 HDEV6
1) Use only the HDEV5/6 tool kit to repair high-pressure injection valves marked with a hook.
Reference values:
Calibration sleeve: Calibration diameter:
(Combustion chamber sealing
ring)
Spare part number:
(Combustion chamber sealing ring)
Calibration sleeve HDEV5 7.98 mm ± 0.08
7.95 mm ± 0.08
F00VH05101 (black, short) Ø 7.98 mm
F00VH05102 (black, long) Ø 7.95 mm
F00VH05003 (white) Ø 7.95 mm
Calibration sleeve HDEV6 6.45 mm ± 0.08 F00VH05206/208 Ø 6.45 mm
Special sleeve16.30 mm ± 0.08 F00VH05205 Ø 6.35 mm
1) Do not use the HDEV5/6 tool kit.
en-gb | 8 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

Figure 2: Long HDEV (HDEV6 shown as example)
15 Wire ring
16 Decoupling element
17 Support disk
18 O-ring
19 Hydraulic interface
20 Injector tip
21 Loss prevention device (only with HDEV6 long)
24 Groove for combustion chamber sealing ring
25 Electrical interface
Figure 3: Short HDEV (HDEV6 shown as example)
15 Wire ring
16 Decoupling element
17 Support disk
18 O-ring
19 Hydraulic interface
20 Injector tip
24 Groove for combustion chamber sealing ring
25 Electrical interface
2 General Safety Information
WARNING
Read all safety information and instructions!
Failure to follow the safety information and
instructions could result in serious injuries or damage
to materials.
The tool has been specifically designed to repair
HDEV5 and HDEV6 high-pressure injection valves.
The safety and function of the tool can no longer be
ensured if it is misused or modified in ways not
expressly approved by the manufacturer. These
actions could result in personal injury or damage to
materials.
Ensure that all users of the tool are familiar with
these operating instructions, have read them
carefully and have access to them at all times.
Use this tool only for its specified uses. If a part is
lost, replace it only with an original spare part.
In general when carrying out a service, replace the
corresponding spare parts of the affected
interfaces before reinstalling the injector in the
engine/rail, e.g. following intermediate inspections
when carrying out engine trials during the
development phase or after removing the injectors
at the workshop during servicing.
Ensure that the floor is level, stable, and clear of
obstruction.
Wear safety shoes that meet the
ISO 20345, S2 standard.
Once uninstalled, protect the HDEV from
contamination, liquids getting into the HDEV, and
stress in sensitive areas.
If it is necessary to replace the high-pressure
injection valve during servicing, use only a HDEV
that is clean, in its original packaging and not more
than ten years old (see date of manufacture or as
exception: the high-pressure injection valve can be
used following the revision by Robert Bosch GmbH).
Carefully protect the combustion chamber seal
from grease and oil to prevent damage to the
sealing ring or gases escaping from the combustion
chamber when the vehicle is in operation.
Clean the hydraulic interface with a clean, lint-free
cloth prior to installation.
Do not use sandpaper or wire brushes on the
sealing surface of the O-ring on the hydraulic
interface.
en-gb | 9 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

3 Operating Instructions
1. Check that all individual parts of the HDEV5/6
tool kit in the case are complete and clean.
If the HDEV5/6 tool kit is no longer complete or
there are signs it has been tampered with, or is
damaged or soiled, on no account whatsoever
should you use the HDEV5/6 tool kit until the
faulty parts have been replaced.
Use only original tool parts as replacements.
2. Determine which spare part kit for HDEV5 or
HDEV6 is required based on the vehicle
identification/code number.
Information on spare part kit
The spare part kit is configured in accordance
with the technical service request for the
corresponding HDEV.
The spare parts kits for individual Robert
Bosch high-pressure injection valves must be
obtained from the vehicle manufacturer. The
tools wire ring assembly sleeve (11) and hook
for wire ring (3) must not be used in this case.
If specified, the Robert Bosch hold-down
element must also be ordered.
The loss prevention device is only required
when initially installing the high-pressure
injection valve in the rail cup.
If the spare part kit contains an O-ring with a
calibration diameter of 6.30 mm ± 0.08, a
special sleeve is required. Do not use the
calibration sleeves of the HDEV5/6.
3. Remove the high-pressure injection valve as
specified in the workshop documentation of the
vehicle manufacturer.
4. If the loss prevention device on the HDEV6 (long)
breaks and falls into the rail cup when the
injector is being removed, take the loss
prevention device out of the rail cup and dispose
of it.
Reinstall the high-pressure injection valve without
the loss prevention device.
3.1 Replace the combustion chamber
sealing ring and the decoupling
element
3.1.1 Removing the combustion chamber sealing
ring
1. To remove the combustion chamber sealing ring
(14), insert the injector tip (20) carefully into the
guide (22) of the pliers (2). As you do so, position
the combustion chamber sealing ring (14)
between the two jaws (23) of the pliers (2) (see
Figure 4).
NOTICE
Incorrectly positioning the injector tip in the
guide!
When inserting the injector tip, ensure that it is
positioned correctly and is fully in contact.
The diameter of the HDEV6 injector tip is
6 mm. For the position of the HDEV6, see
Figure 4.
The diameter of the HDEV5 injector tip is
8 mm. Insert the injector tip of the HDEV5 into
the guide of the pliers up to the stop.
If the positions in the guide are mixed up, the
tip of the injector could be damaged.
If the injector tip is damaged, replace the HDEV.
Figure 4: Positioning the injector tip of the HDEV6 in
the pliers
2Pliers
14 Combustion chamber sealing ring
22 Guide of pliers
23 Jaws of pliers with cutting edge
2. Close the jaws of the pliers (23) to cut the
combustion chamber sealing ring (14).
3. Take the combustion chamber sealing ring (14)
out of the groove (24).
en-gb | 10 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

4. Clean the groove (24) with a clean, lint-free cloth
and carefully remove residue (e.g. coke deposits)
with a brass wire brush, ensuring that the groove
(24) is not damaged.
NOTICE
Damage to the groove of the combustion
chamber sealing ring!
If the groove is damaged, replace the HDEV.
The damaged HDEV is classified as hazardous
goods and must be disposed of accordingly.
3.1.2 Replacing the decoupling element with
wire ring on the HDEV6
1. Depending on the version of the high-pressure
injection valve, a decoupling element (16) with
wire ring (15) is required during servicing.
For more information, refer to the workshop
manual of the manufacturer or the documentation
of the spare part kit.
2. Remove the decoupling element from the HDEV6
before installing the combustion chamber sealing
ring.
Figure 5: Installation position of the decoupling
element and the wire ring
3Hook for wire ring
15 Wire ring
16 Decoupling element
20 Injector tip
25 Electrical interface
3. To remove the wire ring (15), engage the tip of
the hook (3) from the outside into a protrusion
on the wire ring (15).
CAUTION
Puncture wounds
If the hook slips when removing the wire ring,
puncture wounds could occur.
When detaching the wire ring of the HDEV, do
not grip the tip of the injector.
The wire ring could split when it is being
detached.
Figure 6: Removing the decoupling element and the
wire ring
3Hook for wire ring
15 Wire ring
16 Decoupling element
20 Injector tip
25 Electrical interface
4. Pull up the hook (3) to expand the wire ring (15)
and lever it out of its groove.
5. Pull the wire ring (15) over the tip of the injector
(20) and dispose of it.
6. Remove the previously installed decoupling
element (16) by slipping it over the tip of the
injector (20) without force and dispose of it.
en-gb | 11 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

NOTICE
Damage to the combustion chamber sealing ring!
Always install the decoupling element before
installing the new combustion chamber
sealing ring.
Pushing on the assembly sleeve for the wire
ring could damage the newly installed
combustion chamber sealing ring.
Always replace a damaged combustion
chamber sealing ring.
7. To install the decoupling element (16), slide it
into the correct position over the tip of the
injector (20) loosely.
When installing the decoupling element, ensure
that the smaller outer diameter points towards
the tip of the injector.
NOTICE
Incorrect installation position!
Always install the decoupling element in the
correct position as otherwise the HDEV6 will
malfunction.
Figure 7: Installing the decoupling element
16 Decoupling element
20 Injector tip
24 Groove for combustion chamber sealing ring
25 Electrical interface
Figure 8: Installing the wire ring
11 Assembly sleeve for wire ring
15 Wire ring
16 Decoupling element
20 Injector tip
24 Groove for combustion chamber sealing ring
25 Electrical interface
8. Push the assembly sleeve (11) over the tip of the
injector (20) to the decoupling element (16).
9. Push the new wire ring (15) over the assembly
sleeve (11) by hand to the groove in front of the
decoupling element (16).
NOTICE
Incorrectly installing the decoupling element!
Do not reuse wire rings or previously installed
decoupling elements.
Ensure that the correct decoupling element
has been installed, according to the vehicle
type. For more information, refer to the
ESI[tronic] or the workshop manual of the
vehicle manufacturer.
Before installing the HDEV6, ensure that the
decoupling element with the wire ring is fully
installed in the correct position.
Ensure that the wire ring is completely in the
groove.
en-gb | 12 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

3.1.3 Installing the new combustion chamber
sealing ring
1. Ensure that the surfaces of the new combustion
chamber sealing ring (14) from the spare part kit
are dry and grease-free.
2. Push the new combustion chamber sealing ring
(14) onto the mounting taper (9) for the HDEV6
or the mounting taper (10) for the HDEV5 to the
point where the sealing ring has not yet expanded.
Figure 9: HDEV6 Mounting taper with combustion
chamber sealing ring (unexpanded)
9Mounting taper HDEV6
14 Combustion chamber sealing ring
3. Carefully push the calibration sleeve (8) for the
HDEV6 or the calibration sleeve (7) for the HDEV5
onto the injector tip (20).
Figure 10: Installing the combustion chamber sealing
ring with mounting taper and calibration sleeve
8Calibration pin HDEV6
9Mounting taper HDEV6
14 Combustion chamber sealing ring
20 Injector tip
24 Groove for combustion chamber sealing ring
4. Fit the mounting taper (9) or (10) with the
combustion chamber sealing ring (14) on the tip
of the injector (20).
5. Push the combustion chamber sealing ring (14)
with the calibration pin (6) for HDEV6 or the
calibration pin (4) for HDEV5 into the groove (24)
in one movement (see Figure 11).
NOTICE
Overexpansion of the sealing ring!
If it takes more than three seconds to move the
combustion chamber sealing ring, the Teflon
sealing ring will be expanded for too long.
Shift the sealing ring in one movement within
three seconds.
Replace the sealing ring if the sealing ring has
been overexpanded.
Figure 11: Positioning the combustion chamber sealing
ring on the HDEV6
6Calibration pin HDEV6
8Calibration sleeve HDEV6
9Mounting taper HDEV6
14 Combustion chamber sealing ring
24 Groove for combustion chamber sealing ring
6. Remove the calibration pin (4) or (6) and the
mounting taper (9) or (10) from the tip of the
injector (20).
7. Pull the calibration sleeve (7) or (8) over the
combustion chamber sealing ring (14) by twisting
it roughly 180°. As you do so, avoid exceeding the
maximum force of 350 Nm.
en-gb | 13 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

Figure 12: Calibrating the combustion chamber sealing
ring
8Calibration sleeve HDEV6
14 Combustion chamber sealing ring
20 Injector tip
8. Before installing the HDEV5/6, ensure that the
combustion chamber sealing ring (14) that has
been installed is undamaged and fully functional.
Ensure that there are no bulges or scuffs on the
surface of the combustion chamber sealing ring
(14).
9. Re-measure the outer diameter of the combustion
chamber sealing ring (14) with an outside
micrometer. If the reference value is not reached,
replace the combustion chamber sealing ring (14)
and recalibrate.
NOTICE
Incorrect calibration!
If the combustion chamber sealing ring is
calibrated incorrectly, it will not be possible to
achieve a tight seal. Gases could escape from the
combustion chamber when the vehicle is in
operation.
Use the right calibration sleeve for the
corresponding HDEV.
Use only a calibration sleeve that has not been
damaged or soiled.
Do not oil or grease the combustion chamber
sealing ring.
The measured outer diameter of the
combustion chamber sealing ring must be the
same as the reference value in the table of
reference values provided in the chapter
"General Information".
If the outer diameter of the combustion
chamber sealing ring deviates from the
specified standard dimensions, use only tools
that have been approved by the manufacturer.
en-gb | 14 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

3.2 Replacing the O-ring with the
support disk on the hydraulic
interface
1. To remove the installed O-ring, pull it off with
your fingers and dispose of it (see Figure 13).
NOTICE
Leaks in the hydraulic interface!
If the O-ring or support disk is removed
incorrectly, leaks could occur.
Carefully ensure that there is no dust, lint,
fluids, or other forms of contamination (e.g.
metallic materials) on the hydraulic interface,
the components or in the rail cup.
Do not reuse parts that have been removed.
Figure 13: Removing the O-ring and support disk
17 Support disk
18 O-ring
2. Remove the installed support disk (17) by hand
and dispose of it.
3. Fit the new support disk (17) from the spare part
kit in the correct position.
Figure 14: Fitting the support disk and the O-ring
5Assembly sleeve for O-ring (HDEV6)
17 Support disk
18 O-ring
19 Hydraulic interface
The support disk is fitted correctly if the conical
inner contour of the support disk is resting flat on
the cone of the valve.
4. For HDEV6, push the assembly sleeve (5) onto
the hydraulic interface (19).
5. Push the HDEV6 O-ring (18) over the assembly
sleeve (5) into the groove in the hydraulic
interface (19).
For the HDEV5, carefully push the O-ring (18) into
the groove of the hydraulic interface (19) by hand.
6. To make the high-pressure injection valve easier
to install in the rail cup, coat the O-ring (18) with
a few drops of clean, mineral-based engine oil at
the sealing point.
NOTICE
Incorrectly installing the O-ring!
If the O-ring is installed incorrectly, leaks may
occur.
If the O-ring is damaged during installation, it
must be replaced without fail.
Ensure that engine oil does not enter the HDEV.
en-gb | 15 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

3.3 Using the hold-down element
3.3.1 Replacing the hold-down element
1. Depending on the version of the high-pressure
injection valve, a hold-down element is required
during servicing.
For more information, refer to the workshop
manual of the manufacturer or the documentation
of the spare part kit.
2. To remove the installed hold-down element, pull
it over the hydraulic interface (19) by hand.
In doing so, avoid coming into contact with or
damaging the sensitive hydraulic interface (19).
3. To install the new hold-down element, push it
over the hydraulic interface (19) onto the HDEV6
injector body by hand without applying much
force. As you do so, ensure the hold-down
element is oriented correctly relative to the
connector and does not come into contact with
the hydraulic interface.
Ensure that the new hold-down element is fully in
contact with the valve body and is not touching
the hydraulic interface.
3.4 Installing the HDEV5/6 in the
vehicle
1. Install the functional HDEV5 or HDEV6 after
checking that all service work has been carried
out in accordance with the vehicle manufacturer's
workshop documentation.
2. Ensure that the high-pressure injection valve is
working correctly as specified in the vehicle
manufacturer's workshop documentation.
en-gb | 16 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

4 Inspection and Maintenance
Check that all individual parts of the HDEV5/6 tool kit
in the case are complete and clean.
If the HDEV5/6 tool kit is no longer complete or there
are signs it has been tampered with, or is damaged or
soiled, on no account whatsoever should you use the
HDEV5/6 tool kit until the faulty parts have been
replaced.
Use only original tool parts as replacements.
Inspect the HDEV5/6 tool kit in accordance with all
applicable national regulations and document this
procedure.
Ensure that the HDEV5/6 tool kit is complete and
ensure that it is in good working order before each
use.
Inspect the HDEV5/6 tool kit at least once a year.
Document the inspections in accordance with all
applicable regulations and keep the documentation
in a safe place.
Clean the HDEV5/6 tool kit using only agents that
are not aggressive to the surfaces and do not
cause damage.
Store all parts of the HDEV5/6 tool kit so they are
protected against dirt, oil, and corrosion, and so
they are embedded in the inlay of the case (13).
Only the manufacturer shall perform any necessary
repair work.
NOTICE
Modifications to this product which have not been
expressly approved by the manufacturer will void any
warranty. The manufacturer assumes no liability for
personal injuries or damages to materials which occur
as the result of improper use of this product.
Damaged high-pressure injection valves that can no
longer be used must be classified as hazardous goods
and disposed of accordingly.
Dispose of the HEDV5/6 tool kit only at an authorised
scrap metal collection site.
Contact the manufacturer for any questions:
Robert Bosch GmbH
Franz-Öchsle-Straße 4
73207 Plochingen
Germany
[email protected]
www.boschaftermarket.com
www.downloads.bosch-automotive.com
en-gb | 17 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Germany

Inhaltsverzeichnis – Deutsch
1 Allgemeine Informationen ............................................................................................ 20
2 Allgemeine Sicherheitshinweise .................................................................................. 24
3 Bedienung ..................................................................................................................... 25
3.1 Austausch des Brennraum-Dichtrings und des Entkopplungselementes ................................................ 25
3.1.1 Demontage des Brennraum-Dichtrings .................................................................................................. 25
3.1.2 Austausch des Entkopplungselementes mit Drahtring am HDEV6 ...................................................... 26
3.1.3 Montage des neuen Brennraum-Dichtringes ......................................................................................... 28
3.2 Austausch des O-Rings mit der Stützscheibe an der Hydraulischen Schnittstelle ................................. 30
3.3 Verwendung des Niederhalteelementes ................................................................................................... 31
3.3.1 Austausch des Niederhalteelementes ................................................................................................... 31
3.4 Montage des HDEV5/6 im Fahrzeug ......................................................................................................... 31
4 Prüf- und Wartungshinweise ........................................................................................ 32
de | 19 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Deutschland

1 Allgemeine Informationen
Produktbezeichnung: BTG 5120
Produktbeschreibung: HDEV5/6 Werkzeugsatz
Produkttyp: Werkzeug
Produktnummer: 0 986 615 637
Eigengewicht: 0.75 kg
Bestimmungsgemäße Verwendung:
Austausch des Brennraum-Dichtrings am Bosch-
Benzin-Hochdruck-Einspritz-Ventil (HDEV)
Austausch des O-Rings mit der Stützscheibe am
HDEV6
Austausch des Entkopplungselementes
Verwendungsbedingungen:
Nur für qualifiziertes Werkstattpersonal.
Nur für die von der Robert Bosch GmbH
freigegebenen Arbeiten verwenden.
Nur Originalteile des HDEV5/6 Werkzeugsatzes und
des Ersatzteilkits zum Service von Bosch-Benzin-
Hochdruck-Einspritz-Ventilen (HDEV) verwenden.
Nur in geschlossenen und überdachten
Werkstätten verwenden und das Werkzeug vor
Schmutz, Korrosion und Kondensat geschützt
lagern.
Nur bei einer relativen Luftfeuchtigkeit bis maximal
70 % verwenden und lagern.
Nur mit ausreichendem Licht und guter Sicht
verwenden.
Zur Montage geeignete, saubere und fusselfreie
Schutzhandschuhe verwenden.
Das Eindringen von Fremdkörpern oder
Flüssigkeiten in das HDEV während der
Servicearbeiten unbedingt vermeiden.
Bei Beanspruchung an sensiblen Stellen (z.B.:
Ventilspitze, elektrische Steckverbindung,
hydraulischer Schnittstelle etc.) das HDEV nicht
mehr verwenden.
Kein beschädigtes oder verschmutztes HDEV oder
Ersatzteile verbauen.
Bild 1: HDEV5/6 Werkzeugsatz
de | 20 | BTG 5120
1 689 989 487 | 2020-10-01 Robert Bosch GmbH
Franz-Öchsle-Straße 4
73208 Plochingen
Deutschland