#5 injector removal
 

I am having trouble removing injector number 5 from my 760.

The other 5 put up a hell of a fight, I soaked them in rocol, plus gas, and even under instruction from the injector specialist, Coca cola... It wont budge. Its seen off an injector removal socket.

All other 5 had a hell of an amount of carbon underneath.

So a replacement socket is incoming, Do I have to take the lid off the injection pump to get at it? Are there any ways of getting this swine out easily?

I am contemplating getting the other 5 reconned and trying with a hot engine. But seeing as 5 and 6 were clanging not clicking. This one cant be left.

Guessing that your IP is tilted in towards the engine a little bit too far...

If you have the tools and feel confident in retiming it you could just rotate the IP out of the way, easy since the injector hardlines are already loose. And then retime it (not so easy).

Might work, could try with a wobble extension. I have seen that size socket in a 3/8 drive. That with the thinner 3/8 drive wobble extension might just snake thru there.

In general, (since it appears that yours are really cemented in there) orient the wrench handle so you are pushing or pulling it towards the head, not oriented so you are pulling it away from the head. Some have broken off the injector housing that way. If it starts to turn but is still difficult, turn it back in, then out a little bit, then back in again, back out, etc.

I've managed to bend a t piece before the socket gave way. So I have a sealey 6 point arriving soon. All the lines have been removed so they're not an issue.
I'm sure a 3/8" would snap off on this!

I can just about get a ratchet head (sacrificial)on the socket and a 3 foot scaffolding bar that goes across the rocker cover giving me about a foot of swing.

I'll keep soaking in coke and penetrating oil.
But no, I'm not confident in pump timing.

OK,the injector is out...
I destroyed another 27mm tool trying to remove it.
So after 3 more days of plus gas, I whipped the top section off it and got a regular socket over it. A 5 foot scaff bar and it budged. It fought all the way out. Why I didn't think of that in the first place.

Leverage was your friend! Check the fuel spill nipples carefully. Sometimes a regular socket can upset those when struggling with an obstinate injector.

Yup, Found that the hard way.

The heads now toast...

See my post on the volvoforums...

http://www.volvoforums.org.uk/showth...95#post2121595

Caused by running without injector heat shields?

There were heat shields in there, it took a hell of a lot to extract them from the soot. My guess previous owner reused them on an injector replacement. 3 of the worst had generic nozzles. Just a question, what direction do these shields have to be?

The taper points up towards the injector. It gets crushed down when the injector is installed.

What's the issue you're seeing with the head other than lots of soot in the injector wells? Can't tell from the photos, are the sealing surfaces pitted? You might be able to clean it up rather than pulling it apart.

Fastest/easiest way to get the shields out, btw, is to spin the engine on the starter motor, compression blows them out with no struggle even when they are stuck fast. :)

See the photo in this post; it shows the heat shield upside-down. That is, the side shown facing up in the photo would be installed facing down into the head.