Quick quiz - Volvo injectors

B

Beyond

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Hi mechanic type people. My Volvo 2003T injectors are blowing bubles (seals leaking) and I need to remove them to clean them up. I want to make a tool to make this easier my problem is boats in Spain, I'm in UK and need to get the gadget (Slide hammer) made up here before I go out there later this month. I know its a 17mm spanner size BUT can I assume the thread and size will correspond. ( thread on top of injector, fuel pipe clamp nut) Does anyone KNOW for sure what nut to weld on.
Cheers all B.
 
I have 2 Volvo injector removal tools. Now that I have sold the boat with a 2003 engine so I no need them. They cost around £37 but I would sell one for £13 plus postage. Remember that you have to remove the stud, then the clamp before you can even start to remove the injector. PM me if interested.
 
If the leakage is past the side of the injector, your chances of re-sealing arent good. Efforts to withdraw the injector wont be good for the seal of the copper sleeve the injecttor sits in.

I ended up having to remove the head and replace the sleeves. Not a bad idea anyway since the seal of the sleeve at one end is an O ring and after 15 years ..................

removing the head is easy
 
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Remember that you have to remove the stud, then the clamp before you can even start to remove the injector. PM me if interested.

[/ QUOTE ]Not necessarily, you can use the clamp to draw the injector out by putting a large screwdriver under it. However you will need to give the injectors a long soak in penetrating oil first.
 
The reason I had to buy a puller in the first place was because using a screwdriver to force the clamp up pulled the sleeve right out of the block! Even using penetrating oil id not guarranteed to loosen the injector if the exhaust gases have been bypassing the injector seal and glued the injector in the sleeve. Its much easier and safer to remove the stud.
 
Thanks All for your concern.
There is no problem with the copper head inserts this is a common problem with the turbo 2003, there's a simple mod by fitting an aditional copper seating washer on the base of the injector and cleaning the insert and injector with emery cloth. I was show this mod by an exilant Spanish mechanic. I fixed one cylinder at the beging of last season (cylinder 1 blow out arround the seating ring), after another 150 hours of hard running (sailling in the med) now cylinder No 2 is gassing (the occasional bubble) so I need mod all 3: preventive medicine.
So I have taken PinceMadoc up on his offer.
Thanks again Cheers.
 
dont think this a good idea at all
you will jack up the injector and baffle the injector spray pattern
might look good but def not good for engine long term
 
I now understand Beyonds problem a little better but I do not understand his reference to a slide hammer. Over the past 13 years I have corrected just about every problem possible with 200x series injectors. 'Bubbles' around the top of the injector is a symptom of 2 problems, one easy to cure and one not so easy. For bubbles to happen there must be liquid (fuel) and gas (exhaust). So the fuel leak is cured by using new copper sleeves either side of the fuel pipe banjo and tightening up. The seals can be annealed but it is simply not worth the effort. The other problem of gas escaping is a big problem. I do not like the idea of putting an extra copper seal at the bottom of the injector sleeve as it will change the spray pattern. The sleeve and the tip of the injector must be thoroughly cleaned. I glued a piece of wet and dry onto a piece of dowel and flattened the base of the seal. I have heard of using smooth grinding paste successfully.

Do not overtighten the clamp, this is often the cause in the first place as next time its replaced it must go tighter until the the base of the sleeve deforms. Do not force the injector out by levering the clamp up with a screw driver. This can and does cause major damage, I know to my cost! Use the proper puller which has 2 legs that sit onto the top end of the sleeve a a bolt attached to the injector top and running through a threaded boss.

I have decided not to sell the pullers separately. I have a lot of spared and tools for the 200x and so I will write an advert to sell the lot at once.
 
SO..... back to my original question. <span style="color:red"> DOES ANYONE ACTUALLY KNOW THE THREAD SIZE ON THE TOP OF THE INJECTOR?</span> So I can get the B. thing made. /forums/images/graemlins/mad.gif
 
there is only one thread on top of the injector and its for the return fuel .. are you not close to your engine so you can see it you must go to the manual for the enginge. i have a 2003T so i have a pdf manal....
if you are intending to remove the injectors they are no windings if they are stuck there is a puller for this job
 
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I have 2 Volvo injector removal tools. Now that I have sold the boat with a 2003 engine so I no need them. They cost around £37 but I would sell one for £13 plus postage. Remember that you have to remove the stud, then the clamp before you can even start to remove the injector. PM me if interested.

[/ QUOTE ] /forums/images/graemlins/laugh.gif

What is it with you guy's?

I don't want a lesson in engine maintenance. I just need to make a f tool.
 
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