200 tdi

Anyone know how to remove a injector from a 200 TDI the main body has come out but the nozzle end stuck in block

Have you dismantled the injector in situ or have you pulled it out and the nozzle bit snapped off, have you a pic of whats left you have removed , may need to copy and paste pic
Welcome to Landyzone btw

It was stuck in block I heated it up wiggled it and the top half came out the nozzle end stuck in block I'll get a pic for you no problem

steve2286w said:

Have you dismantled the injector in situ or have you pulled it out and the nozzle bit snapped off, have you a pic of whats left you have removed , may need to copy and paste pic
Welcome to Landyzone btw

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Will not let me copy and paste neither upload a file sorry

There’s a problem on website , but you can copy and paste photos, once clamp removed they should pull out but if you turn them anti-clockwise you can unscrew them apart so they look like below, or the bits have pulled apart

Ok it's the bottom part 2 on the left of pic are stuck in head

So has the 1st part on left come out too and just the small diameter bit of the 2nd part from left( nozzle)

Yep the bottom pics and the injector nozzle stuck

So if the nozzle is stuck in that will keep the nozzle holder in too so that’s both parts on left
If that’s the case I think you need to remove any loose bits ie spring and locator and put some release oil/ diesel in hole and leave for a couple of days
Then screw top part into nozzle holder and turn only clockwise to break the friction
If engine running you could put injector pipe into big clean pop bottle cover loosen clamp a few threads and start engine this might heat up and force it out
If no success then try a big adjustable/spanner on the flats of injector and bang it round with hammer the shocks might vibrate it and or use a short pipe extension over the spanner for extra leverage

if the only bit stuck is the thin part of nozzle which has broken off off then you may need to remove head and knock it out from inside with a 6”nail with the point filed to suit

The thread is also damaged on the bottom one when the main body screws into it I was thinking of removing the nozzle and maybe then a bolt extractor

That makes it a lot harder, I’ve cleaned up damaged threads before using a bolt with hacksaw cut along its length , might work with the injector end Or a tap to recut the threads in the end of the nozzle, it depends whether the tight bit is the nozzle or the end cap

The thread is broken a peace of the end cap do can't do anything with thread

You may very well be looking at pulling the cylinder head off to get the nozzle out

ifloochies said:

You may very well be looking at pulling the cylinder head off to get the nozzle out

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I'm hoping not to would I need new cylinder bolts if I done it

Ok , the hole is flat bottomed and I recall the end cap is fairly thin walled, where it’s not it could be drilled out further then ground out
I recently did a front hub bearing on a Corsa and had to remove the outer shell from the hub, I bought a dremel 3000/4000 and used cutting disc which worked really well so depending on what’s left in a screw extractor might get it out or might be head off job also

Tomjones12 said:

I'm hoping not to would I need new cylinder bolts if I done it

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Depends on condition but need a new gasket

Thanks I hope it comes out as definitely don't want to strip half the engine to take head of to get injector out I'm on a tight schedule

Can you run it and see if nozzle shoots out , protect with 4x2

What shall I do with the injector pipe

See if it will swivel out of way and collect diesel in pop bottle