Volvo Penta 2003 injector sleeve

[tyce]

I have an exhaust leak on my VP 2003 from No1 Injector which i am guessing means the injector sleeve probably needs changing.
I want to do it myself as i dont want the cylinder head lying around in some Volvo Penta dealers workshop for weeks wasting the summer while some one gets around to doing it.
Only problem is the workshop manual makes reference to the special tools required to do it, these are-
p/n 884811 Expanding screw (for getting the old one out)
p/n 884557 Mandrel (for knocking new one in)
p/n 884283 Flaring tool (this looks to be the most critical and i cant find one for sale anywhere)

Does anyone have a set the'd like to sell or rent or have knowledge of where they can be obtained or an alternative.
Any info on the job would be much appreciated.

 

[Heckler]

I have an exhaust leak on my VP 2003 from No1 Injector which i am guessing means the injector sleeve probably needs changing.
I want to do it myself as i dont want the cylinder head lying around in some Volvo Penta dealers workshop for weeks wasting the summer while some one gets around to doing it.
Only problem is the workshop manual makes reference to the special tools required to do it, these are-
p/n 884811 Expanding screw (for getting the old one out)
p/n 884557 Mandrel (for knocking new one in)
p/n 884283 Flaring tool (this looks to be the most critical and i cant find one for sale anywhere)

Does anyone have a set the'd like to sell or rent or have knowledge of where they can be obtained or an alternative.
Any info on the job would be much appreciated.

Give Juggler a PM, he had a set of tools for sale a while back
Stu

 

[smeaks]

I am aware of the feeling of "bodging" this job but.... I had just the same blowpast on an injectror. I removed the injector and cleaned up the sleeve/injector interface and used an annealed copper washer in the fashion of how a "normal" injector seals. Once bedded and torqued up this has worked perfectly for three years with little smpke and almost immediate starting. I know I have perhaps altered the injection height of the injector and possibly affected the spray pattern... but it works and my engine appears happy. When i read about the sleeve replacement I thought it posed many more problems through missfiting (it acts as the seal for the jacket water from entering the cynlinder?) and so took the route I did one afternoon. It was going to be a temporay fix, but I am happy to leave it as it has proved adequate and effective.

I do hope this post is not the kiss of death!

 

[pvb]

I wouldn't rush to take the head off. Try removing the injector, cleaning up the base of the sleeve and the seating surface of the injector, reassembling. Maybe a careful tap with a mallet on top of the injector to help ensure it's fully seated. If that doesn't work, I'd also be tempted to try popping a very thin copper washer in the hole as the next possible fix.

If the head does have to come off, I see no reason why it should end up "lying around in some Volvo Penta dealers workshop for weeks"; my experience of VP dealers is that they can turn things around very quickly if they're properly briefed.

 

[BarryT]

As PVB says, try cleaning the base of the sleeve and injector. I did this sucessfully by using a very small amount of grinding paste on the bottom of the injector. You need to be careful to avoid bits falling into the cylinder though.

 

[tyce]

Thanks all for helpful advice, i must admit head removal and sleeve replacement was the worst case and was going to try cleaning up the sleeve first, i just have a horrible feeling the sleeve will come out with the injector.
I like the idea of grinding paste, i was thinking about a injector seat cutter and hadnt thought about paste like stated if done with moderate amounts and carefully should work well.
I also thought about a thin copper washer and it has to be worth a try if not to just get me through to winter.
I am going to the boat tomorrow so will let you know how it goes.
Thanks everyone.

 

[smeaks]

The injector should jack out against the sleeve if use the puller. If you don't have a puller soak the injector in loads of release oil before prising it. Also try twisting to break any carbon seal prior to prising the injector.

 

[Happydaze]

You may find that the sleeve moves when you get the injector out in which case you have no choise but to replace it. It's best to use a straight pull using a reversible hammer and not try to twist it out. I reseated all my injectors a few years ago, first i made up a tool to scrape the copper seat on the end of a tube and that worked on 2 of them and the third needed the grinding paste to finish off.

 

[smeaks]

I have an extractor tool on the boat that jacks the injector out against the sleeve so the latter does not move. It also means you do not need to remove the stud because it works around it. This ensures the injector sleeve does not move. If you can wait till after the weekend I can post it to you and then return it to me afterwards. It is on the boat at the moment and I won't get down till Sunday.

 

[tyce]

Hi Smeaks, what a very kind offer, unfortunately i dashe down the boat this morning without first spotting your post but thanks for the kind offer.
I managed to get the injector out with some serious hard grunt, it was well and truly stuck due to the carbon building up along the length of it but at least i got it out in the end.
I tried lapping it in with grinding paste but this method was unsuccesful so tried a copper washer which has very much improved it but not cured it so i am going to see how it goes over the next week or so, if it gets no worse i will live with it until the end of the season.
Thanks for everyones help.

 

[smeaks]

Hi Smeaks, what a very kind offer, unfortunately i dashe down the boat this morning without first spotting your post but thanks for the kind offer.
I managed to get the injector out with some serious hard grunt, it was well and truly stuck due to the carbon building up along the length of it but at least i got it out in the end.
I tried lapping it in with grinding paste but this method was unsuccesful so tried a copper washer which has very much improved it but not cured it so i am going to see how it goes over the next week or so, if it gets no worse i will live with it until the end of the season.
Thanks for everyones help.

If it is a general washer it will leak. My first attempt was with a standard washer. I then used a diesel injector washer off a cat or similar. Heat to cherry red then quench. Once fitted and talked down I still got some blow past but..... A diesel fitter pal of mine used a socket on the injector end to protect the threads and gave the injector a hefty clout then with a hammer we retorqued and got a half turn or so on the clamp. Did this a couple of times and the blow past sealed up great. You can get a good sealing washer from any diesel fitter. He had an md7 and we did his to with gret success.