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I bet this has never happened before! (td5 Help!!)


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I replaced the injector seal washers and o-rings, it all went very smoothly.


While replacing the metal clips that secure the injector harness plug, the clip slipped out of my hand and fell down a hole into the engine - I attached a photo - I can just see part of the clip, and can't reach it to get it out.


So my question is/are

where does the hole go?

how far would i need to dismantle the engine to get to it?

will it cause damage to the engine if I can't get it out?


Any help/advise greatly appreciated.


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I'm glad not to be the only one to have done this!

Thanks for the kind offer Mike. Unless you live near Austria I won't be able to take you up on it unfortunately.

The clip is wedged behind one of the bolts securing the cylinder head. I tried one of the other clips and found that is only very weakly attracted to a magnet, not enough to lift it with.

If I can't get it out i'm guessing the head will have to come off, but thats way above my skill level, and now I can't even drive it to a garage.

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I have a "grabber" device, on a flexible shaft of the Boden cable type. Pressing

the button on the end opens out three slim metal fingers at the other end, release

and they close up around the inaccessible item.

Business end is about 1/4" dia. One of these may do the trick if magnets wont work.

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I've got one of those screwdrivers that you can change the heads on. This has a telescopic magnet that you can pull out and would be useful for this sort of thing, but i would have thought anything like that would work.

I would try the magnet before the extendy claw thing as i find my one takes a couple of tries to find the best way to 'grab' things sometimes and you dont want to drop the clip and force it further into the engine!!

Good luck!

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thanks for the suggestions folks.

I don't know what metal the clip is made of, but its not attracted to a magnet!

It's stuck about 4 inches down, and the shaft is too small to get the claw thing in.

I'll try with a variety of hooks today, and if theres no joy I may get an endoscope as a last resort.

I don't think the clip does any harm where it is, but I worry that with vibrations and oil getting pumped around that it could find its way into the oil pump or a moving part that could be damaged.

Will keep trying

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Where does the hole go, anyone? I assume you mean the square-ish one?

I'd have thought most of these holes in heads just return to the crankcase and therefore sump, be surprised if it caused any issue in there, and could remove at a later oil change if you wanted by dropping the sump off.

If you can get to it with something straight, what about a thin piece of steel with a tiny bend on the end to form a hook?

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http://item.mobileweb.ebay.co.uk/viewitem?itemId=150985701990&kw=150985701990

Maryland laparoscopic forceps...

or try Tilleys Forceps much cheaper (I normally use these for getting various things put of toddlers ears/nose)

http://item.mobileweb.ebay.co.uk/viewitem?itemId=160978723213&kw=160978723213

Crocodile forceps

http://item.mobileweb.ebay.co.uk/viewitem?itemId=160946093959&index=1&nav=SEARCH&nid=13384804306

There's lots of surgical instruments that are useful for working on cars, I have a small stock of expired and used instruments!

Mike

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Take one of the loudspeakers out of the dash and use a steel rod or wire with the speaker core against its top end - speakers have strong magnetic fields and the field will be conducted down the rod or wire when kept in contact with the speaker.

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I'd expect the glue to become oil covered and useless, or to stick to something else on the way down.

If the clip is non-feritic, I'd suggest a narrow tube adapted to fit a vacuum cleaner. A length of silicone windscreen hose, copper brake pipe or plastic fuel pipe through a tin can lid taped across the hose from a vacuum cleaner should work very well.

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  • 2 weeks later...

Thanks for all the suggestions!

I made a video with a borrowed endoscope: http://www.youtube.com/watch?v=2Yg4YcxWFKY&feature=youtu.be

My faffing around has caused the clip to fall behind the cylinder head bolt you can see in the film.

I'm going to refit the rocker cover and see what happens.

Can anyone tell me where the clip might end up now?

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http://item.mobileweb.ebay.co.uk/viewitem?itemId=150985701990&kw=150985701990

Maryland laparoscopic forceps...

or try Tilleys Forceps much cheaper (I normally use these for getting various things put of toddlers ears/nose)

http://item.mobileweb.ebay.co.uk/viewitem?itemId=160978723213&kw=160978723213

Crocodile forceps

http://item.mobileweb.ebay.co.uk/viewitem?itemId=160946093959&index=1&nav=SEARCH&nid=13384804306

There's lots of surgical instruments that are useful for working on cars, I have a small stock of expired and used instruments!

Mike

They look like they would be pretty good at removing the bit of mig wire that has , apparently, fused itself to my sternum......

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