stuck injector Volvo 2003T and noisey engine

[queensrevenge]

Hello:

I am looking for some help. I have an injector that I am trying to pull out of my Volvo 2003 however it will not move. I tried to loosen it up with a vise grips and I am finding that the copper sleeve is moving with the injector; not good I know. This was all precipitated by the fact that my engine was very noisy. Initially I thought it might be valve clearances, or bent pushrods; all check out. The noise which is louder than lifters in my estimation - might be a faulty injector? hence my attempt to pull the injectors (2 came out easy!) My next step is to take off the head and bring it into the shop, pull injector and replace copper sleeves. I am planning to have the valves done as well.

Any further thoughts would be appreciated.

Ed in St. John's Newfoundland Canada

 

[peterN]

Have you tried a slide hammer? This is the correct tool for removing the injectors and should be available for hire or borrow from wherever you are going to get your injectors serviced. You need to get the appropriate fitting for the screw thread on the top of the injector (inlet pipe), but they should have one if they deal in Bosch injectors. The last time I borrowed one to pull my 2003T injectors was in Australia so I can't help with a UK contact.

Good luck,

Peter

 

[mandlmaunder]

usual remedy +---trow it away ,buy Yanmar- problem solved.
or find replacement injector pipe before sawing thru pipe.
If engine sounds like Ippitombi have taken up residence in sump then crank shaft shell bearing is shot or top end sleeve bearing gone on holiday .

 

[nigelhudson]

I had a sticking injector on my 2002. I used a proper penetrating oil (not WD 40) and created a little puddle round the injector. Then I worked the injector from side to side - there is just a lttle bit of play in the tube. I repeated this exercise every day for a week and then was able to withdraw the injector. The penetrating oil had not dissolved the gum right to the bottom of the tube but it was far enough. I didn't use a wrench on the injector - I used a spanner as a lever to pull the yoke upwards which brought the injector with it.

 

[wotayottie]

Since the copper sleeve has moved you have no option but to take the head off and replace the sleeve. It is rumoured that its possible to replace the sleeve with the head in situ, but I wouldnt risk it.

With the head out and on a bench, I got the stuck injector out using a steel wedge between the head and the clamp. But there is a proper Volvo tool.

There are also Volvo tools for doing the sleeves and having seen mine done I would chose next time to buy the tools and DIY. Flog the tools afterwards to the next unlucky sailor.

Doing the valves is another easy diy - the best approach since its an old engine and wouldnt reward lots of spending at the volvo dealer

 

[robind]

Volvo do a proper puller for about £30-00 but too late now! you hve o fit a new copper insert! It is possible to do it with the head on!

 

[queensrevenge]

Hello:
I am back to report that I took the head off , replaced the copper sleeves; replaced oils seals around valves and had the valves lapped. All for about $800 canadian. However, the noise is still there. Also, checked out injectors and they are good.

Any further thoughts, anyone have trouble with the turbo and would that produce a knocking in the engine.

Thanks

Ed

 

[Stemar]

Worn cam followers can make quite a bit of noise even though all the clearances seem OK. Slop in the timing gears will add to the noise, but apart from the excess decibels, they're irrelevant.

Turbos are usually pretty trouble-free until they run short of oil in their bearings Due to the speed and temperature, they are lubricated under pressure. Wear in the bearings knackers the oil seals and the oil gets sucked into the engine. An audible whine is a sign of impeding problems but there's not much you can once it starts to go. It takes a while for it to get really bad and you'll know when it does. I had this on a turbo diesel Golf once and laid a cloud of smoke down the motorway that practically closed it. /forums/images/graemlins/tongue.gif

Avoid it by starting at low revs or cranking the engine until the oil pressure comes up with the stop pulled out before starting from cold, and allow the engine to idle for a few minutes before stopping it after it's been working hard.

 

[queensrevenge]

Thank you for thei information. I had the cam followers checked out. They checked out.

It looks like I will have to get the Volvo Penta Mechanic down to the boat .

Ed