Volvo 2003T fuel injector removal

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dawnsall

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I want to remove the fuel injectors from my Volvo 2003T. There is no specific injector removing tool listed. Keyparts don’t do one. I obviously want to get it right and not loosen the copper sleeves. I have already drained the water cooling system and they are soaking in penetrating oil. They were removed 5 years ago by a mechanic and it’s the first time I’ve done it myself. They have now done 1200 hours.
I would like some advise from somebody who has personal experience of doing it themselves please. Thank you
 
I did manage to remove the single injector from my 2001 this winter without the special tool. Started with 48 hours soak in penetrating oil. Then hit the problem that you can't remove the yoke in order to get a spanner on to the flats of the injector because its its held down by a nut on a stud. Obviously you can remove the nut but you can't release the yoke (not sure why not assembled with a bolt which would sort this problem). Anyway, found that an old gas pipe elbow (1/4 or 3/8" bsp) fitted thread on top of injector and used this to very gently wiggle and twist. It started to move a little bit and then just kept going with more penetrating oil - and eventually hey presto.
 
Sorry, further to my previous post I had to remove the stud before I could remove yoke - by locking two 'thin' nuts together (filed thin because length of protruding stud too short to fit 2 standard nuts). This also allowed use of spanner to assist in the wriggle technique.
 
I borrowed a specific tool too remove mine. A tube goes round the injector and sits on the flange of the copper sleave, a fitting screws onto the injector thread and allows you to safely draw it out.
 
Make a sliding hammer.
Use a nut the same size as the top of the injector, weld rod to this( friendly welder) with a weight slide onto the rod. Rod must be at least 9'' long with a washer welded on the top, to stop the weight flying off. Screw this to top of injector and slide weight up several times. Works every time.
 
Thanks all, it looks like I need to make a tool. However although the sliding hammer is a good way of removing the injector I think I will have to make a puller that works by pushing against the copper sleeve as these are prone to pull out with the injector on these engines. thanks.
 
An engineer at Volvo in Sweden said i should have used a slide hammer to remove the injectors, that was after i had loosened the sleeve in the first one by twisting the injector which resulted in head off and into the workshop for replacement. Expensive mistake but engine has been much better with the valves re-ground.
 
I'm not sure now what to do, by using a sliding hammer I would not have to remove the retaining yoke studs. I had thought that having to remove the studs to remove the injectors seemed a bit daft. I guess I will try the sliding hammer and be prepared to take the head off if I dislodge the sleeves. I have read that the head removal is not a big deal!! Thanks all for input.
 
It's true that gead removal isn't a huge deal.

Gaskets from Keyparts will only induce a mild heart attack rather than the full-on cardiac arrest Volvo prices are likely to provoke.

If you do take it off, strip the valves out (keep track of which one goes where!) and regrind them. If they're too bad, get valves and seats recut by a car engine reboring co first. After I did this on mine, the decompresser shaft needed easing (angle grinder) to get the necessary clearance on the valves.

If you're going to all the trouble of removing the injectors, I assume you're going to get them reconditioned. If you're in the area, Panda diesel in Fareham sorted me out after Lucas made a complete bollox of mine. I know where I'll go first next time!

From bitter experience, the injection pumps are firmly in the "If it ain't broke, don't fix it" category. Their gaskets are actually shims that calibrate the pump, and the setting is important. They ain't cheap to do either! Unless you've got good reason to believe they're faulty, I'd leave well alone.
 
problem is - if your injectors are well seized in the sleeves with carbon (as mine were) then even if you get them out you will have problems cleaning up the bottom of the copper sleeve well enough to seal properly. Put a copper washer in there and you mess up the injection pattern.

I whipped the head off myself (easy job) and replaced all three sleeves.
 
Thanks for all advice I think the best thing to do is the injectors, sleeves, and valves while I'm at it. The engine is 20 yrs old and has been reliable so I guess it deserves it.
 
sheigra said:
I borrowed a specific tool too remove mine. A tube goes round the injector and sits on the flange of the copper sleave, a fitting screws onto the injector thread and allows you to safely draw it out.
Click to expand...
Is this a tool that was made or is it supplied by some tool company, either way can you give me more details of the removal tool/ or who supplies it please.
Thanks in advance.
 
sheigra said:
I borrowed a specific tool too remove mine. A tube goes round the injector and sits on the flange of the copper sleave, a fitting screws onto the injector thread and allows you to safely draw it out.
Click to expand...
This is the best way ie you jack against the top of the sleeve. There may be a way of achieving this by making a U plate to sit under the injector body and on the sleeve and jack against this.
 
I believe that the tool for this was also used on tmd30/40 engines but only lasted a few uses before collapsing on either.
minI mum requirement is that water be drained to avoid damage if the sleeve moves
I also think that their may have been early and late injector’s and sleeves
removing stud was normally recommended
I have been retired over a decade so my memory is not. That good a nd no longer have access to VP books so see how this stacks up against other information
 
Cillcais said:
Is this a tool that was made or is it supplied by some tool company, either way can you give me more details of the removal tool/ or who supplies it please.
Thanks in advance.
Click to expand...
I make and stock injector pullers in various sizes - they attach to the threaded section where the injector diesel pipe goes, common sizes are M14 x 1.5 & M12 x 1.5, and they have the split tube to press against the sleeve to prevent pulling that out at the same time
 
DinghyMan said:
I make and stock injector pullers in various sizes - they attach to the threaded section where the injector diesel pipe goes, common sizes are M14 x 1.5 & M12 x 1.5, and they have the split tube to press against the sleeve to prevent pulling that out at the same time
Click to expand...
Can you supply to Ireland please
 
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