Volvo D5 - Removing stuck/seized Diesel Injectors

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Removing injectors on a Direct-Injection Diesel engine will always have the potential to ruin your plans - I anticipated this one well in advance, and had to resort to a slide-hammer extractor kit to remove one.
(Apologies for the inconsistent audio quality - I had a bit of hardware failure making the video!)

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23 окт 2021

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Комментарии : 14

@matthewwiddows6319 Год назад

for others watching, if you have a leaking injector thats showing that black tar around it and your thinking of sorting in the future as the car is running ok at the moment. keep regularly applying carb cleaner and then use an air duster on a compressor to blow down the injector hole. this will slowly release all the crud.

@simpgod917 3 месяца назад

Where do I apply the carb cleaner?

@matthewwiddows6319 3 месяца назад

@simpgod917 just spray over the black tar around injectors, it will help keep it soft. Also have learned after doing a few more, clean when engine is hot, tar softens with heat.

@svenladegast2518 2 года назад

There is a slide hammer which grips onto the lower edge of the body. I used this to extract 2 of the injectors that were stuck on my engine. The advantage is that the injectors did not get destroyed. Cleaning is easy with a rotating wire brush, even at the nozzle portion. They looked and work like new when I took them back in. The secret is to get the injector moving by turning it and get the engine pretty hot in the forefront. So 30+ miles on the motorway is a good idea. Always make sure to use new copper washers, new retaining clips and retaining screws when re-inserting injectors or they WILL start to leak again. Although these parts are pretty expensive, it is worth the money.

@Jeroen74 2 года назад

The retaining ring on Euro 3 injectors are a nightmare to get off and on, I had a coworker turn a thin 19mm tube on a lathe much like the Volvo tool for me, and even then it was not easy. I recently bought a 2009 S60 and before delivery they changed the inlet manifold gasket. I was surprised to see on the workorder they hadn't replaced the screws/retainers of the injectors, just the washer and HP pipes. And that was a maindealer!

@MuddyBiker 2 года назад

Look forward to seeing the next step 😬

@claywebb8199 Год назад

I’ve removed a stubborn injector before by warming the engine up then loosening the retaining bolt very slightly (if they are that design) and fired up the engine again. The combination pressure dislodged the stubborn injector.

@cookstrap 2 года назад

Hi Chris did you replace with new injector or second hand ? 1👍

@wheeldesire 2 года назад

Hi Ian Second hand did the trick. I managed to get one for £12 including postage, then a new set of bosch leak off clips was around £3, and the injector copper seals (F00VC17503) were around £5 delivered for a set. On the 163 (pre-DPF) engine, there's no apparent 'coding' of the injectors, save for matching the code that's on the injector solenoid (number within a circle on the top - mine was '2'). I have long done the job but not found time but the 'bigger' video, but I found little need to replace the clamps and pipes, as is suggested by Volvo. That makes a big difference as these things are getting towards the age/value where £600+ in new parts for an otherwise routine job would otherwise be edging them towards the breakers yard.

@cookstrap 2 года назад

@@wheeldesire thank you very much

@rasmuzt9260 Год назад

do you know the thread size you used? And do you ruin the injector if you do this?

@wheeldesire Год назад

Not specifically. I bought a kit that came with various sized threads. I did ruin the injector I pulled, but by this point I'd likely ruined it anyway. You can get less aggressive attachments that fit under the injector body

@MrZakmuh 2 года назад

Try removing the injector without removing the solenoid actuator ( the top connector housing). This messes up the calibration. You will have to recalibrate it through a diesel or injector specialist or replace the entire injector with a used working one. You don't have to code/programme the replacement injector but Bosh's part number should match number to number. Volvo's part number irrelevant. Volvo's injector puller or similar is the one to use than this tool.