freeagent Posted December 30, 2007 Share Posted December 30, 2007 I've bought a new set of injectors for my 300Tdi... but i don't seem to be able to get the old ones out.... I removed the fuel pipe, the spill pipe fittings and the clamp which holds the injector in place... at this point the Haynes manual says 'withdraw the injector' but mine is stuck solid.. i cant get a spanner on it to rotate it, and don't wan't to start levering it as don't want to damage it.. is there a puller you can buy to remove them? the new ones do look like they just push in, so i don't think i'm missing something obvious.. any tips or tricks i should know... Quote Link to comment Share on other sites More sharing options...
Les Henson Posted December 30, 2007 Share Posted December 30, 2007 Diesel Jim had the same problem as you and made a tool that attaches to a slide hammer which got them out no problem. Les. Quote Link to comment Share on other sites More sharing options...
TheRecklessEngineer Posted December 30, 2007 Share Posted December 30, 2007 Either use a slide hammer....or use the very unsafe and not recommended method: Put a thick towel, or lots of cloth over the top of the injector in question, and spin the engine over...the compression will fire the injector out of its hole. Quote Link to comment Share on other sites More sharing options...
freeagent Posted December 30, 2007 Author Share Posted December 30, 2007 james, I like your idea... but it sounds like the slide hammer route might be safer... any other suggestions would be most welcome... Quote Link to comment Share on other sites More sharing options...
yella 90 Posted December 30, 2007 Share Posted December 30, 2007 i get the engine upto normal op temp to remove stuck injectors ok, everything is a tad warm but hasnt failed to work yet Quote Link to comment Share on other sites More sharing options...
Guest diesel_jim Posted December 30, 2007 Share Posted December 30, 2007 As Les said, i used a slidehammer. i just got two nuts (one that fitted the end of the slidehmmer and one that fitted the thread of the injectors), welded them together and then hammered away, ahem, so to speak... ) If you're anywhere near swindon and want to borrow it, just shout. Quote Link to comment Share on other sites More sharing options...
western Posted December 30, 2007 Share Posted December 30, 2007 not that close ------ northfleet and southend. Quote Link to comment Share on other sites More sharing options...
Exmoor Beast Posted December 30, 2007 Share Posted December 30, 2007 The tech forum is your friend Injector removal Will Quote Link to comment Share on other sites More sharing options...
Guest diesel_jim Posted December 30, 2007 Share Posted December 30, 2007 ^^^^ That would be even better if i hadn't deleted the piccies from photobucket... think i'll be re-writing it tonight and attaching the piccies instead! Quote Link to comment Share on other sites More sharing options...
Guest WALFY Posted December 30, 2007 Share Posted December 30, 2007 It did seem to be lacking a bit without pics :D Quote Link to comment Share on other sites More sharing options...
Guest diesel_jim Posted December 30, 2007 Share Posted December 30, 2007 Try again: Injector removal on 200 or 300Tdi engines. OK, so you’ve got some new injectors to install, and the old ones just won’t budge? I had this on the engine I’m building up in my garage, also on my 90 when I changed them last year, they just wouldn’t budge an inch (or a millimeter!) Even after soaking them in WD40 and trying to turn them with a spanner they wouldn’t shift. The tool you need is a slide hammer. This is basically a shaft, about 12~15mm diameter, with a large weight, about 3lb or so, that can slide up and down. There is a threaded end and the other end has a large flange bit to stop the weight coming off. On the threaded end you can attach a variety of things, like a wheel bearing puller, a “dent puller”, a pair of mole grips, or whatever… In this case, you need to attach the injectors…. So, easiest (and only way!) is to get a nut that fits the thread on the injectors (on the 300Tdi it’s M14x1.5) and one that fits the end of the slide hammer. These need joining together… with a welder. Blue tack just won’t hack it I’m afraid. after welding: Once you’ve made the adaptor, simply screw it to the slide hammer, then onto the stuck injector, then pummel away! pummeling! : Mine wouldn’t move even after this, and luckily I have the engine mounted on a movable frame, so I could turn it 180 degrees so that I was sliding the weight “downwards”, and had the added benefit of gravity helping me. This way, the injectors came straight out. As you can see by the state of them, there was a fair bit of rust around them. The new ones will obviously be clean, and a liberal coating of copper-slip might help, but as they don’t get changed that often, I’d imagine that the anti-seize compound will be dried out/jetwashed out before it has any chance to actually do it’s job. Quote Link to comment Share on other sites More sharing options...
freeagent Posted December 30, 2007 Author Share Posted December 30, 2007 that is excellent, many thanks to all of you, especially diesel Jim. I do have a new set of injectors but don't want to trash the ones fitted at the moment as I was planning to get them reconditioned at some point.. All i need to do now is find out where i can get 1 off M14 x1.5 nut without having to buy a box of 100... Quote Link to comment Share on other sites More sharing options...
Guest diesel_jim Posted December 31, 2007 Share Posted December 31, 2007 All i need to do now is find out where i can get 1 off M14 x1.5 nut without having to buy a box of 100... I'm sure i've got a spare one from when i made that adaptor up. PM me if you want it, i'll fling it in the post. Quote Link to comment Share on other sites More sharing options...
JimAttrill Posted December 31, 2007 Share Posted December 31, 2007 Unfortunately the nut is not a 'standard' size. But making a slide hammer is the best way - I welded the nut to a bit of tube with a large old gear wheel as a weight. Works a charm without damaging anything. Quote Link to comment Share on other sites More sharing options...
Guest diesel_jim Posted December 31, 2007 Share Posted December 31, 2007 Good idea that Jim. B) B) i suppose anything "heavy" that will slide on something thin would do, some decent threaded bar and a stub axle might do as well! Quote Link to comment Share on other sites More sharing options...
simonb Posted January 1, 2008 Share Posted January 1, 2008 Or use an open ended spanner on the flats of the injector to wiggle it round left and right in the hole to loosen, then with spanner still on and its shaft resting on the clamp pin and stud, strike opposite end of spanner with a hammer a few times and the injector will pop out. This method has worked for me several times. Quote Link to comment Share on other sites More sharing options...
Bluemoon Posted December 17, 2012 Share Posted December 17, 2012 If you don't have access to a welder , bolt a heavy weight to bit of chain bolted to the injecter nut, quite effective Quote Link to comment Share on other sites More sharing options...
vulcan bomber Posted December 17, 2012 Share Posted December 17, 2012 And when the injector breaks you'll need to do something like this: Quote Link to comment Share on other sites More sharing options...
dave88sw Posted December 17, 2012 Share Posted December 17, 2012 I had one incredibly stuck one, in the end i got it out by using a nut threaded down the top until it stopped, then continued turning, turning the injector in its hole (its round so it wont damage it rotating it). It went with one hell of a bang Quote Link to comment Share on other sites More sharing options...
nicks90 Posted December 18, 2012 Share Posted December 18, 2012 i cheated when i changed mine. Loosened off the nuts and fired the engine up for 5 seconds took the fuel pipes + nuts off and they all came out in my hand edited to add - engine only ran for 5 seconds as once the injectors had loosened in their holes, all the cylinder compressions dropped and it stalled the engine. Easy way of knowing they were loosend off! Quote Link to comment Share on other sites More sharing options...
cackshifter Posted December 18, 2012 Share Posted December 18, 2012 As the injectors are steel in an ali head,they should be looser when the engine is warm Quote Link to comment Share on other sites More sharing options...
Stevie D Posted December 18, 2012 Share Posted December 18, 2012 Did the same with the slide hammer and spanner - hot engine etc - eventually shifted. Some car wheel nuts / bolts are m14 x 1.5 hat's what I had handy Steve Quote Link to comment Share on other sites More sharing options...
cackshifter Posted December 18, 2012 Share Posted December 18, 2012 BTW if you use a (maybe makeshift) slidehammer don't put a finger between the fixed bit on the end and the slider or let a bit of hand hang over the end of the slider....ask me how I know Quote Link to comment Share on other sites More sharing options...
Deej Posted April 10, 2013 Share Posted April 10, 2013 I'm about to tackle this problem, and I also don't have a slide hammer. I agree that using compression to shoot the injectors out sounds a bit dangerous, but as someone else has mentioned if you just loosen the retainers slightly then surely that will allow the injectors to be freed without turning into a projectile. Or am I missing something? Quote Link to comment Share on other sites More sharing options...
muddy Posted April 10, 2013 Share Posted April 10, 2013 I have the top 8" ish inches of an intector pipe with union this means you can screw it on the wiggle the injector body whilst pulling upwards with the pipe usually works. Will. Quote Link to comment Share on other sites More sharing options...
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