2001 TD4. It was leaking fuel from somewhere, forming puddles of diesel around the top of the engine where the injectors sit. I couldnt see an obvious leak, but there was pressure blowing back from around one of the injectors. Turns out that one of the studs that hold it down had stripped its threads. Someone has been at it before me as there are a few snapped studs and other broken bodgery.
I need to get the injectors out to remove the cam cover so I can helicoil the head to get the studs fitted properly. 3 came out easily enough (the leaky one had no copper washer at the bottom) but number 2 is stuck like a mofo.
No amount of wiggling or levering shifted it. I made up a bit to fit a slide hammer onto the top of it but that had no effect. Eventually I damaged the housing of the solenoid on the top, so decided to sacrifice it and removed the big nut that screws to the top of the injector body. I welded this nut to the slide hammer, but the threads gave up after a few hits. Having resigned myself to buying a new injector, I got a bit of M18 stud and welded it directly to the top of the injector, made up a hook on the other end and have the engine hoist pulling it. I can lift the entire front off the ground without the bloody thing shifting. By hammering on the pipe union, I can get it to turn in its hole, although fittings and other stuff in the way limit it to about 10 degrees of movement, so its not completely seized, but there is too much friction for it to pull out.
I have left it hanging by the injector on the hoist tonight to see if it shifts, but failing that I am running out of ideas.
I may have to smash/cut off the cam cover around it to get more space, then if I still cant get it out the bloody head might have to come off.
Anyone got any ideas or suggestions?
I need to get the injectors out to remove the cam cover so I can helicoil the head to get the studs fitted properly. 3 came out easily enough (the leaky one had no copper washer at the bottom) but number 2 is stuck like a mofo.
No amount of wiggling or levering shifted it. I made up a bit to fit a slide hammer onto the top of it but that had no effect. Eventually I damaged the housing of the solenoid on the top, so decided to sacrifice it and removed the big nut that screws to the top of the injector body. I welded this nut to the slide hammer, but the threads gave up after a few hits. Having resigned myself to buying a new injector, I got a bit of M18 stud and welded it directly to the top of the injector, made up a hook on the other end and have the engine hoist pulling it. I can lift the entire front off the ground without the bloody thing shifting. By hammering on the pipe union, I can get it to turn in its hole, although fittings and other stuff in the way limit it to about 10 degrees of movement, so its not completely seized, but there is too much friction for it to pull out.
I have left it hanging by the injector on the hoist tonight to see if it shifts, but failing that I am running out of ideas.
I may have to smash/cut off the cam cover around it to get more space, then if I still cant get it out the bloody head might have to come off.
Anyone got any ideas or suggestions?
