Volvo 2003 injector sleve the out come

[mldpt]

Hi After all the helpfull advice from my last posting about the removal of the injector sleve on my 2003. I returned to Jersey removed the injector to find that the copper seat and the seat on the injector were both damaged, I attempted to remove th emarks in th ecopper seat by polishing it with a suitable sized wodden dowel with grinding paste this removed most of the grove in it, reasembled it all was fine untill I put it in gear and put some load on it it blew again.
I borrowed the tools to remove the sleve but it would not budge, so I removed the head drilled out the swaged end of the sleve hopeing that the tool would then pull it out but no still helf fast even though the wall thickness in the head was only .025" in the end I purchased a Dremmel and ground the sleve out taking care not to damage the head, what a job now I have to find a way of cleaning the waterways of all the copper swarf, any ideas how to do this I guess I will have to wash it throughly with petrol or something like that. If only I had tried a copper washer first. I am now having a problem getting the Injector resurfaced, I had an exchange one on order at £80 which was ok but then there seems some doubt as to wether this part no is correct for my engine even Volvo don't seem to know, the only one they can send which they are sure is correct is £250 so I have left it with a guy in St Helier who thinks he can get another end nut for it so I live in hopes. I doesn't always pay to do the job the way the books says.
Regards Mike

 

[wotayottie]

had the same issue last year and did all three just to be sure - the rubber sealing rings do go with time. Machine shop had no great problem rmoving the sleeves though their standard practise was to drill the swage.

Guess you havent bought the head gasket etc yet - otherwise the injector would seem reasonable.

 

[mldpt]

Hi I thought I had a spare head gasket but when I found it, it was the rocker gasket, I am aware that the gasket is not cheap, I think from what I remember last time I did an engine overhaul its cheaper to buy a full gasket set hence I have a spare rocker gasket. The seals are ok it was the seats in the copper sleve and on the injector that were leaking, anyway I have got the sleve out now and hope to get it running on my next visit to Jersey in Jan 2008
Regards Mike

 

[colvic987]

On my md7a,I ended up taking the head off myself and getting the volvo agent to fit new sleeves to the head, they did a great job, new sleeves and replaced all o rings in the head, (for the valves i think, all around 5 years ago, so a little vague on the memory) and repainted the head, approx £300, and £100 for the head gasket, £24 for the rocker cover gasket and £8 for the breather gasket on top of the rocker cover, so not a cheap solution, but it all went back on ok and has been great since..