AUTOiNFORM ONLINE MAGAZINE: Removing seized vehicle injectors

AUTOiNFORM ONLINE MAGAZINE: Removing seized vehicle injectors


hello and welcome to or to inform online magazine how to in this issue would like to look at the problem of injector removal I’d like to explain what’s happened with regards to our involvement in this process and how we’ve arrived at the decision we have to bring in a specialist this physical vehicle was brought to us with a best scrub as uneven lumpy running engine we conducted some pretty basic it’s common rail diesel wash system conducted some fairly basic tests one of which was a bank leakage test which is conducted by checking the spill volume out of that port on the top of the injector as a result of that there was a considerable imbalance in the four injectors so we recommended to have those injectors refurbished and then to continue the further Diagnostics once that particular fault had been resolved that’s when the problems began to stack up out of the four injectors we managed to get two of them out fairly easily one of them were the degree of difficulty using what I would call a fairly basic puller which we have whereby we remove the solenoid and use a slide hammer which screws around the top of the injector we then came to inject number one the one that we’re actually dealing with now and despite all efforts of further dismantling the injector using a slightly different puller pulling directly on the center of the body suspending the injector using an engine hoist introducing heat application of various fluids downside of injector it was clear this injector wasn’t going to go anywhere facing with a dilemma if that injectors and come out the engine scrap or at least very expensive repair process there on in and possible loss of the work in fact I think it was pretty much decided by the owner if that was a case the vehicle would have been I assume scrubbed not wishing to lose the profit of the opportunity of repair we then brought in Tony of ap auto diagnostics’ his website also carries the same name and with special tool so as part of this how-to I’d like to introduce Tony is part of our network membership and also a friend and leave his expertise to explain what he’s doing how it’s doing it and of course you can then observe the result so I’d like to pass you over to Tony all right thank you Frank this engine is suffering from one of what was becoming a very common fault these days which is the seasoned injector scenario this appears to be being caused by a combination of corrosion carbon bypassing the seal and just general detect detritus going down from the top there appears to be concrete in the injectors into the engine to an extreme standard where the only thing that will actually remove the injector is a dramatic amount of force as you can see we’ve already set up the puller previously on the engine so that we can get a significant amount of force into the job this puller uses a 10 ton ram and basically pulls in a very straight direct manner this allows the injector to come out fairly easily which can set a lot of you guys because it makes the job look too easy and that is basically it there is no sort of overcomplicated method involved the actual injector itself you need to remove the solenoid from the top of the injector being careful not to remove the spring and the calibration washer inside then you need to remove the internal parts of the injector which which then frees up a much stronger internal thread this external thread on the injector is only very thin-walled very weak and is very easy to break off most slide hammers will actually use that thread and a lot of the injectors I’m called out to have already got that thread torn off right simple enough we use the principle of hydraulics so I simply now – now the pull is all set up I simply pump the pump steady aware and the injector will slowly rise out of the engine I don’t know if you can see the gauge but you’ll see that this is taken on average about five tons of force a slide hammer at a maximum is only capable of actually applying approximately a ton and a half that allowed bang that you heard was actually the injector releasing as it comes up and again once we get to the end of the travel on the ramp we just need to release the pressure take up any slack in the system and then start again this method while this work is actually repeated over and over again until the injector all the way out as the injector comes out false required will gradually reduce to the point where the injector is out and there she is one season injector removed just a kiss now of Frank steam clearing out the hall where the injector belongs Britt cutting the seat fit in the new injector with a new seal and job done they got Frank thank you Tony and from our point of view this decision should have been made a little earlier and we did arrive at it we tried our best I think the lesson to be learned from the meet watching this process the first time is that in the short instance when these injectors are obviously tight and you have a choice you can invest in the tools are expensive they require specialist equipment to knowledge to to apply and often out on the economic even for us we are specialists we would not consider buying this tool because we would feel the opportunity of using the tool would not justify the cost and with the expertise of Tony on hand and this type of work is much better subcontracted we can now get on with the repair Tony suggested we’re going to relieve some of the corrosion around the bore recut the seats and provide for new injectors and then we can get the vehicle back on the road so my thanks to turn it and I hope you’ve enjoyed this month’s how to thank you you


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