dave21478

Active Member
2001 TD4. It was leaking fuel from somewhere, forming puddles of diesel around the top of the engine where the injectors sit. I couldnt see an obvious leak, but there was pressure blowing back from around one of the injectors. Turns out that one of the studs that hold it down had stripped its threads. Someone has been at it before me as there are a few snapped studs and other broken bodgery.
I need to get the injectors out to remove the cam cover so I can helicoil the head to get the studs fitted properly. 3 came out easily enough (the leaky one had no copper washer at the bottom) but number 2 is stuck like a mofo.
No amount of wiggling or levering shifted it. I made up a bit to fit a slide hammer onto the top of it but that had no effect. Eventually I damaged the housing of the solenoid on the top, so decided to sacrifice it and removed the big nut that screws to the top of the injector body. I welded this nut to the slide hammer, but the threads gave up after a few hits. Having resigned myself to buying a new injector, I got a bit of M18 stud and welded it directly to the top of the injector, made up a hook on the other end and have the engine hoist pulling it. I can lift the entire front off the ground without the bloody thing shifting. By hammering on the pipe union, I can get it to turn in its hole, although fittings and other stuff in the way limit it to about 10 degrees of movement, so its not completely seized, but there is too much friction for it to pull out.

I have left it hanging by the injector on the hoist tonight to see if it shifts, but failing that I am running out of ideas.
I may have to smash/cut off the cam cover around it to get more space, then if I still cant get it out the bloody head might have to come off.

Anyone got any ideas or suggestions?
 
Also, I have just had a thought - the few degrees of rotation I can get........I wonder if maybe the tip is fully seized and the injector body is unscrewing and re-tightening by those few degrees?
 
Also, I have just had a thought - the few degrees of rotation I can get........I wonder if maybe the tip is fully seized and the injector body is unscrewing and re-tightening by those few degrees?
drop angleloc a pm he had problems lik e this and may be able to help
 
If you do a search on the web, there are companies who have specialist pullers that will be able to get it out with out having to damage anything else. Normally if you give it a good soaking in penetrating oil they usually do eventually come out, but from what you have tried that may not work for you.
As for the one with the copper washer missing, you may find it is stuck in the bottom of the seat, if so you must get it out prior to refitting.
 
if it is seized as you say you would not be able to turn it pulling on a engine hoist may not be at the right angle if you get me
 
Yes, they slope backwards, almost parallel with the windscreen, but I had the car on a steep slope with the engine hoist up on blocks so it was pulling the injector straight "upwards" along its axis.



All for nowt though, I got it out this morning.

Over the last few days I have been systematically drenching it in carb cleaner. This morning I made up a longer, heavier slide-hammer and welded it to the stud I already had in place. This gave me about 1.5m of travel for the weight, which is a head from a massive old sledge hammer. I put some large foam sheets across the windscreen and roof, stood on the engine and went Full Retard for a few minutes.
After a load of hits, it suddenly came loose and the slide hammer went flying from my hands, over the roof and landed about 10 feet away.


Need to source a replacement injector now and then send them away to get tested / refurbed if needed, then helicoil the head and rebuild it all.
 
Yes, they slope backwards, almost parallel with the windscreen, but I had the car on a steep slope with the engine hoist up on blocks so it was pulling the injector straight "upwards" along its axis.



All for nowt though, I got it out this morning.

Over the last few days I have been systematically drenching it in carb cleaner. This morning I made up a longer, heavier slide-hammer and welded it to the stud I already had in place. This gave me about 1.5m of travel for the weight, which is a head from a massive old sledge hammer. I put some large foam sheets across the windscreen and roof, stood on the engine and went Full Retard for a few minutes.
After a load of hits, it suddenly came loose and the slide hammer went flying from my hands, over the roof and landed about 10 feet away.


Need to source a replacement injector now and then send them away to get tested / refurbed if needed, then helicoil the head and rebuild it all.

you should have videoed that
 
nice one just take your time if you can on the rebuild and all should be well i have a injector that leeks on mine sometimes I need to do it again soon and brought some of those special bolts can not believe the cost for shuch a small thing I do replace the copper seal at the bottom and all is fine for a while the suddenly leaks a little
 
nice one just take your time if you can on the rebuild and all should be well i have a injector that leeks on mine sometimes I need to do it again soon and brought some of those special bolts can not believe the cost for shuch a small thing I do replace the copper seal at the bottom and all is fine for a while the suddenly leaks a little

You need to clean the seat the injector sits on - the bit below the copper washer - I bought a tool for doing this off eBay about £20 I think - it works well and means the seal is good. Also make sure the sides of the tube the injector goes in are clean as this can also hold the injector up off it's seat.
 
hi angeloc what was it called is there any special name for it remeber I told you about getting all the black out but you can never be sure you have it all out I forgot to mention last time that I also used a spray gun cleaning brush it is just a nice fit and round but still it could leave bits in
 
hi angeloc what was it called is there any special name for it remeber I told you about getting all the black out but you can never be sure you have it all out I forgot to mention last time that I also used a spray gun cleaning brush it is just a nice fit and round but still it could leave bits in

Hi - here it is if thus URL works

7pc Diesel Injector Seat Cutter Set Cleaner Decarbonise carbon clean B5533

http://7pc Diesel Injector Seat Cutter Set Cleaner Decarbonise carbon clean B5533

It is £40 plus my mistake - great bit of kit though. I smeared a bit of grease on the appropriate cutter - make sure you use the right one (flat) and it brings up all the rubbish with it.
 
This is the tool I made to get a stuck injector out.
inj006.jpg


inj008.jpg


See this thread.
http://www.landyzone.co.uk/lz/f9/td4-injector-removal-48915-2.html

Allan
 

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