200TDI Fuel Injector Removal - It's being a pig!

+1 on that. Its close to right, do as little as possible to disturb that.

Thanks all. Finally managed to budge the stubborn sod. Got my new injectors back today. Just a quick question. I have some thin gauge coppers washers spare new and old. The ones they came with are very heavy gauge. I'll speak to the supplier too, just wondered if anyone has used any other washers other than standard? Thanks

As I mentioned earlier I had issues on my Sprinter with genuine MB sealing washer which was solved by using Honda ones.
But I'd take the advice of the injector supplier.

Thanks. will anneal and use supplier washers. Also, No.4 left a pretty corroded mess, cleaned up we'll though. I'm hoping no crap worked its way inside. I should think the washer would have prevented that. All other holes were ok, a touch or carbon build up. From experience, would anyone say corrosion like this could cause a problem? Injector wasn't salvageable sadly as I expected, so hoping that's the only downside to No.4 thanks all

I use a smear of copper slip on my injectors to facilitate removal at a later date if needed,

Europa486 said:

I use a smear of copper slip on my injectors to facilitate removal at a later date if needed,

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Good Idea, I got some german made cermic based stuff which is apparently great for diesel injectors, mainly MB. Will smear some of that on there. Pretty sure they've never been removed in 28 years, I will be checking injectors from now on every 6 months to a year. Thanks again for all the help, greatly appreciated.

Straw or thin plastic tube taped into a Hoover crevice tool & insert into cylinder via the injector hole to clean out as much as possible
Don't get caught by your other half

You defo need to clean that hole out.
i have used a snug fitting screwdriver in the small hole then blown the dirt out with an airline, a little dust/dirt in the cylinder bore will do no harm.

lynall said:

You defo need to clean that hole out.
i have used a snug fitting screwdriver in the small hole then blown the dirt out with an airline, a little dust/dirt in the cylinder bore will do no harm.

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Got it as clean as I could. The others cane up much better.

That looks like it would benefit from a seat cutter.
You could try fitting your injector with a new washer & see what happens.

Ratae said:

That looks like it would benefit from a seat cutter.
You could try fitting your injector with a new washer & see what happens.

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I did try with the seat cutter, but I couldn't really judge how much is was taking out and the tool doesn;t seem to be the right size. I thought it needs to be 20mm x 17mm, but I've only got 21mm x 17mm. It did clean it up a little, but seems to be an easier job with the head off, which I don't really fancy doing. The washers the refurbed injectors came with were much thicker than standard, so I'm hoping they'll be fine. If no joy and I get problems I think I'll have to remove the cylinder head to do some proper cleaning. I'm replacing glow plugs next, so will probably end up removing the head to get them out, though hoping they don't snap! plenty of plus gas and easy does it for them me thinks.