volvo injector seating?

[Birdseye]

peering at the rear injector on my 2003, I can see a tiny bubble blowing up round the base in the little pool of oil that has dripped from the previously leaky rocker box gasket.

how are volvo injectors sealed? is there a plain copper washer underneath? any chance of getting away with just removing, cleaning and re-seating? do I really have to drain the engine to remove the injector?

 

[capsco]

First and easiest solution may be to loosen the injector and twist it round a little then retighten, evenly, if there are two nuts.

 

[old_salt]

Remove the injector and copper washer.
Clean the copper washer throughly by degreasing or washing in soap and water.
Heat up the washer by hanging it on a length of steel wire 'old wire coat hanger' over a cooker ring, or a hot air gun paint stripper on full heat should do it.
Do not grip with pliers or anything that will indent it when hot. Heat it up to blood red and "drop" it in clean cold water that will anneal it, do not over heat, 'bright red', that will only harm it.
Alternatively just heat up and let it cool.
Replace as explained by capsco.

 

[pvb]

There isn\'t a washer...

There isn't a washer, so your advice doesn't help at all.

The injector sits in a copper sleeve which is swaged into the head. It might be possible to reseal the injector by just removing it, cleaning it and refitting. The yoke which holds it down needs torquing to 20Nm.

If this doesn't work, and leakage becomes a problem, the proper fix is to renew the copper sleeve. There's a special tool for removing it, and it's really a head off job.

 

[old_salt]

Re: There isn\'t a washer...

Yes you are quite right I missed that point that engine has a copper sleeve pressed in to the cylinder head.
Auntie seize paste and careful torquing down with new nuts may have the desired effect.
As you say the only proper fix is renew the copper sleeve.

 

[Birdseye]

Re: There isn\'t a washer...

I'll have a go at lapping in with a little bit of fine grinding paste - assuming that I can get the injector out of course.

 

[andy_wilson]

?

There is no lapping in to do with an injector. the nut on the end of the injector sits straight against the base of the copper sleeve. First stop should be to torque the injector clamp to 20Nm - no more, see below.

I've just had the head off this winter to refurb, prompted by a leaking injector as you describe, which was caused by a stripped, overtightened nut.

You will probably find it difficult to remove due to a syrupy mixture of diesel and carbon that has been blowing past the seal.

If it won't come out easily, start soaking it with diesel to free it, and get a second nut on the stud for the clamp and take the stud out, that way you will be able to remove the clamp and work the injector carefully out. If you go at it too hard you may disturb the copper sleeve. Do that and you will have to get the head off to replace it. This alledgedly needs three tools, one to remove, one to insert, and one to flare it into place, for which an agent will charge the apropriate rate.

Once the injector is out, the problem is to clean up the inside of the sleeve without crap falling into the cylinder, hence I whipped the head off, cleaned the sleeves with a plumbers wire brush designed for cleaning inside 'Yorkshire' copper joints, had the injectors refurbed, lapped the valves in to clean up the pitting, and generally fettled it up.

My injector man supplied me with 2 v.thin copper washers to drop down the hole before refitting to aid the seal. I refitted them with copious 'copperslop', and bought a pair of new nuts for the injector studs.

Cyl. head gasket / seal set for my 2002 was about £55.00 from Keyparts (non-gen).

 

[gmccomb]

Re: ?

I noticed that there was engine fumes ((Volvo 2002)in the boat towards the end of last season. Unfortunately I was very busy during the winter and I have just started on the boat for this season. There is a carbon build up around the top of the rear injector. I filled around the top of the injector with WD40 today and turned the engine over and there were bubbles came up so I presume there is a leak. Questions are. A. is there a seal I can replace or does the sleeve need changed or is there a sealant?
B. I tried to get both the injectors out without success. Is there a known trick to this. P.S. I did have them out about three years ago without any problems but this time seems to be a problem.

thanks in advance for your replies

 

[scottie]

DO NOT FIT WASHERS

you can try cleaning the sleeves with the volvo brush