A fix for a blowing injector in a Volvo P 2003

[Roger_D]

Picked up boat in perfect working order..from previous owner....Sure enough next day (sunday in Oban) fumes below and a phut phut noise from the engine. I could feel the gases blowing past the third injector.....books of word out...dire warnings of pulling out the copper sleeve with the injector without special tools etc. Local off duty Samaritan mechanic said he always had to force them (the sleeves) out (by threading them internally). He gave me a small copper washer to fit at the seating of the injector onto the sleeve (and lent me his toolkit-mine then being a little deficient.) Gently eased out the injector with a mole wrench and popped the washer in ..and it worked!... now carry spare washers for the others jic. Tools went back with a litre of Scotland's finest. V happy, disaster averted. (Volvo would have had the head off, & sleeve replaced...this may yet happen, but so far so good....15hrs so far)

 

[TRH]

Hi my advise,Would be to keep the washer as thin as possible,So as not to upset the spray pattern of the injector

 

[Roger_D]

Yes, good point, I don't know how far into the chamber the spray ports are, however, the malleablity of the copper combined with some thickness is required to ensure that a seal is made under the pressure of the injector resulting from tightening up the fork on the head. Screwed in injectors would be much better in this regard. Thanks

 

[jax]

I supose there is a reason why injectors are held down with a yoke (as i've always seen) and not threaded in. Enlighten me anyone?

 

[wotayottie]

Just had the head off to replace the copper sleeves - not a difficult job and one you could do yourself since the Volvo tools arent that expensive. The injector tip doesnt protrude very far into the cylinder so the washer will have messed up the spray pattern almost however thin a washer you use. What that means in practise, I dont know. If it works ..................... /forums/images/graemlins/grin.gif /forums/images/graemlins/grin.gif /forums/images/graemlins/grin.gif /forums/images/graemlins/grin.gif

 

[Roger_D]

looks like another job for winter then. Why did you have to replace the sleeves? Blow by?

 

[GrahamC]

My 2002 had the same problem, replaced the leaking one and a month later the other went. Opinion of Macdonalds at Kip was to renew both. There is a little "O" ring that seals the water jacket at the top end and if the engine has been "cooked" no cooling water then you may also get water mixed with diesel on the cylinder head. Macdonald's lent me both tools under deposit. The washer idea is a temporary repair, I would do it properly and have the injectors serviced at the same time, lap in the valves and decoke the pistons, clean the water galleries and renew the valve seals . Worth it for the peace of mind. Happy to say its all right now,
GrahamC

 

[KRG]

Just had mine done, VP2002, the boat was filling with fumes and the engine went 'hiss, hiss' when starting. Mechanic said he'd never seen one as bad. Had the top end cleaned up and valves ground at same time.

Engine is now much quieter and smoother, well worth doing properly but i like your washer idea as a temp fix.

Mine went close to home mooring so wasn't a problem but had it gone whilst cruising it would have been a show stopper.

The fumes made going below almost impossible, I don't usually suffer sea sickness but even a quick dash below was enough to make me queasy.

 

[Roger_D]

The last head and short engine overhaul I did was on a Peugeot 505 deisel, it had an alloy head and screw in injectors & non of this faf with copper sleeves & subsequent failings, I wonder why they have them.....then I bought a boat, so back to lapping in valves...

 

[GrahamC]

The copper obviously conducts heat away from the injector and stops fuel vaporising before its injected into the cylinder, the injectors are Bosch and they can be part exchanged. Lawson Diesel in Edinburgh charged £120 for two complete overhauls and test, which I thought was very fair
Regards
GrahmC

 

[Roger_D]

I see your point about the copper..but the 505 managed without. £120.. was that for an overhaul of the head (lapping valves, new valvel seals) including new sleeves? In which case v good.