Unashamed tech question.Injectors Volvo 40A. Removal of..

[oldgit]

One of my diesel injectors(No 5) after a couple of thousand hours or so has decided to play up.This appears in the form of not working on tickover and only bursting into life when the revs are increased.Try as I might cannot see any logical reason why a complete no hoper like me cannot whip them out and get them up to my local Bosch dealer and get them looked at merely using a socket and ring spanner.
My query is,have always been under the impression that to do so without a "special tool" is tantamount to madness,but despite looking at my genuine workshop manual and assorted online diagrams cannot see anything by way of sleeves etc that can cause problems.Only appears to be a washer anmd "o" ring that seems incapable of going anywhere other than out with the injector.
Feel free to reveal the calamity that awaits

 

[Wiggo]

Assuming they're the same as the KAD42/43 injectors, they sit in a sleeve that's pressed into the head. If you remove the injector without using the proper puller (only about £25) you risk pulling the sleeve as well and that will open the coolant gallery in the head allowing water to pour down into the cylinder.

 

[dragoon]

Hi,
not wishing to disagree with Wiggo, if these are 40's (as in TAMD/AQAD40 or similar), then I don't believe they have the same issue as the 42.

I have 40's and have removed the injectors without issues. After disconnecting the fuel pipe, remove (with the single nut) the "crows-foot" that holds it in, get a pair of mole grips firmly clamped onto the injector, wiggle and pull straight (don't twist it).

There is a brass sealing washer immediately beneath the injector which will require replacement (or annealing). Don't turn the engine over with the injector out, as there is a nozzle/washer arrangement further down the hole which will fly out with great speed!

Maybe VolvoPaul or someone can comment on the risk for coolant (as I forget if I drained the coolant the last time I had these out). Really I don't think it was an issue though.

Cheers,
Paul

 

[oldgit]

Thanks for those taking trouble to reply.They are the really ancient AQD40A around 130hp on a very good day.All head diagrams show is a solid casting around the injector hole.A search of the special tools section a back of book does not turn up any special tool for the job. ?

 

[Kawasaki]

As per Wiggo
Give Key Parts a bell
Removal tool fer 25 quid, makes the job simps

 

[PCUK]

If as suggested these are the older type with just a sealing washer, then a puller is not needed. They are the same as any other make of engine with this type of injector.

 

[Wiggo]

I sit corrected, in that case. Crack on. Though if you want to make it a simple job, a slide hammer with an adaptor to screw on to the top of the injector is the way forward...

 

[oldgit]

I sit corrected, in that case. Crack on. Though if you want to make it a simple job, a slide hammer with an adaptor to screw on to the top of the injector is the way forward...

Thanks all,will v. carefully oik one out and have a look.If all OK will whip them all out and get them off to be checked.
My manual very helpfully goes into worrying detail about dismantling injectors and which shim/spring combination to use for opening pressures,will probably not go down that route as it does not seem to involve my strong points meaning hammers and other blunt instrument technology..