tdi300 injector removal.

[Blknight.aus]

ok heres one for you all......


how the hell do you get the uberstuck injectors out of a tdi300...


between me, greyknight and jik22 weve thrown everything at it and now were stuck with 2 injectors not coming out....

I thought we got them early in the piece when as per the manual turning them with a spanner got them freed up but nooooo. all that was was the body spinning in the cap....

we tried the weld a nut on top and slide hammer it out and that didnt work, we bent the improvised slide hammer.

attempting to hydraulic one of them out just pushed the nozzle up out of the cap.


given the condition of the glow plugs and the#1+#2 injectors that came out with just the slightest twist of a spanner and levering them up from the side.

Im guessing that the #3+#4 injectors havent been changed and neither were the glowplugs.

The heads off for strip down now as Im thinking that the only things left that we can do that arent in my book of extra nasty tricks is taking it to a machine shop and having them ream the bodies out of the bores.

My book of semi safe and sane butchery has come to the last page and Im open to suggestions....

[justinc]

ok heres one for you all......


how the hell do you get the uberstuck injectors out of a tdi300...


between me, greyknight and jik22 weve thrown everything at it and now were stuck with 2 injectors not coming out....

I thought we got them early in the piece when as per the manual turning them with a spanner got them freed up but nooooo. all that was was the body spinning in the cap....

we tried the weld a nut on top and slide hammer it out and that didnt work, we bent the improvised slide hammer.

attempting to hydraulic one of them out just pushed the nozzle up out of the cap.


given the condition of the glow plugs and the#1+#2 injectors that came out with just the slightest twist of a spanner and levering them up from the side.

Im guessing that the #3+#4 injectors havent been changed and neither were the glowplugs.

The heads off for strip down now as Im thinking that the only things left that we can do that arent in my book of extra nasty tricks is taking it to a machine shop and having them ream the bodies out of the bores.

My book of semi safe and sane butchery has come to the last page and Im open to suggestions....

Hi Dave, forgot you are over that side of the planet:D

Unfortunately this is a case where you need to be left alone in a room with the head and some power tools:twisted:
I have had to heat until VERY HOT the injector body and then allow to cool, then soak with CRC/ penetrant etc and STILL have to bash them out with a blunt instrument:mad::mad::mad:
Obviously the injector becomes a mantlepiece ornament but at least the head will be OK.
It is not uncommon, but make sure that when you get them out, that the reason they are stuck in there isn't that coolant has seeped into the gap around the injector. When we were doing Jock the Rocks engine inspection the head was cracked through there and an injector was 'part of the head':(

JC
JC

[87County]

FWIW, when I changed mine (in the D1) and I had to use unspeakable strong-arm levering techniques (incl BFH on the lever (choose a stable fulcrum point :))) to pull the old ones which were heavily carboned around the business end....

I fortunately didn't have to take the head off (although after reading several threads on this site, it mighn be a good idea to change the head gasket anyway) :)

regards - Laurie

[Bigbjorn]

Not familiar with them. Can you get the the centre out of them leaving the shell stuck in the head? If so you may be able to tap a thread into the shell and use a nut and bolt to extract the shell.

[Blknight.aus]

Hi Dave, forgot you are over that side of the planet:D

Unfortunately this is a case where you need to be left alone in a room with the head and some power tools:twisted:
I have had to heat until VERY HOT the injector body and then allow to cool, then soak with CRC/ penetrant etc and STILL have to bash them out with a blunt instrument:mad::mad::mad:
Obviously the injector becomes a mantlepiece ornament but at least the head will be OK.
It is not uncommon, but make sure that when you get them out, that the reason they are stuck in there isn't that coolant has seeped into the gap around the injector. When we were doing Jock the Rocks engine inspection the head was cracked through there and an injector was 'part of the head':(

JC
JC

Cheers JC thats what I was thinking but I didnt want to go that way as I dont like local cooking up of the ally heads Ive seen it come unstuck in a "you need a new head" kind of way....

we did the heat it up with sunlight and leave it soaking with penetrant thing as par for the course and still had no joy.

jik22 is trying to get hold of a machine shop through his brother in law that should be able to drill/ream to depth the injector hole.

I'll jury rig a pressure tester and leave the injectors and glow plugs out till I can pressure test the cooling system half of the block.


Disgustingly this is the deepest Ive ever had to turn in my book of safe and sane butchery to remove an injector from a TDI and now it looks like the opening pages of the not so safe book are going to hold the answer.

Cheers for the backup on that JC I didnt want to go there if it was virgin ground.

[Blknight.aus]

Not familiar with them. Can you get the the centre out of them leaving the shell stuck in the head? If so you may be able to tap a thread into the shell and use a nut and bolt to extract the shell.

thought of that and the only taps that I have access to are fairly coarse and are likely to cut all the way through the injector cap and into the ally If I try them.

ive only got about 1 maybe 2mm of wall thickness to work with on the cap side of the injector.

[Bigbjorn]

thought of that and the only taps that I have access to are fairly coarse and are likely to cut all the way through the injector cap and into the ally If I try them.

ive only got about 1 maybe 2mm of wall thickness to work with on the cap side of the injector.

I have 20, 24, & 26tpi taps up to 1" but not much use to you when you are over in Sandland.

[jik22]

jik22 is trying to get hold of a machine shop through his brother in law that should be able to drill/ream to depth the injector hole.

Awaiting a call back as we speak....failing that, get the petrol and matches ready for when I come round. :o

[PAT303]

If you have to butcher them I have four injectors you can have if you aren't buying new ones. Pat

[Ace]

Just buy a new cylinder head, preserving your mental health has to be worth that at least. :D Its a pain when seemingly little things like that are the only things standing between you and finishing a job.

Good luck with it mate, im not sure if i need to buy a new head or not yet for mine, but i might get bruce davis to swap mine over if they are still ok to use for a while.

[justinc]

Cheers JC thats what I was thinking but I didnt want to go that way as I dont like local cooking up of the ally heads Ive seen it come unstuck in a "you need a new head" kind of way....

we did the heat it up with sunlight and leave it soaking with penetrant thing as par for the course and still had no joy.

jik22 is trying to get hold of a machine shop through his brother in law that should be able to drill/ream to depth the injector hole.

I'll jury rig a pressure tester and leave the injectors and glow plugs out till I can pressure test the cooling system half of the block.


Disgustingly this is the deepest Ive ever had to turn in my book of safe and sane butchery to remove an injector from a TDI and now it looks like the opening pages of the not so safe book are going to hold the answer.

Cheers for the backup on that JC I didnt want to go there if it was virgin ground.


Hi Dave,

Use a BIGGISH oxy tip and heat it QUICKLY so as not to spend TOO much time near the head:o You'll find that the fact that there is a solid membrane of carbon seperating the injector from the head it shouldn't actually transfer a LOT of heat. The trick is to heat it fast and then take away the heat. A bit like welding around inside a brg cone to get it out of a housing, it'll shrink when it cools:)
Go for it, I know you can do it!!!

JC

[jik22]

If you have to butcher them I have four injectors you can have if you aren't buying new ones. Pat

Thanks for the offer. I have four new injectors already though, and it was the seemingly simple job of fitting them that caused the problem to begin with.

However, after a session on a mill with a big drill bit they are at least out, so tomorrow we'll know if the head survived the job when we put it back on.

[Blknight.aus]

Hi Dave,

Use a BIGGISH oxy tip and heat it QUICKLY so as not to spend TOO much time near the head:o You'll find that the fact that there is a solid membrane of carbon seperating the injector from the head it shouldn't actually transfer a LOT of heat. The trick is to heat it fast and then take away the heat. A bit like welding around inside a brg cone to get it out of a housing, it'll shrink when it cools:)
Go for it, I know you can do it!!!

JC

no oxy...