seized injectors

[realslimshady]

Alongside my current 'oil leak' thread, I have identified the leak but am now stuck as to remove and reseal the black plastic rocker cover I need to remove the injectors, and they are call seized solid.
I have been plying them with WD40 and then Liqui Moly super-duper unseizing agent for 10 days or so, but I still can't budge them.
Just tried putting a blowlamp onto one but the plastic is too close and starts melting.
So. Any tips? I had the same with one on my Voyager but after lots of dousing and wiggling that eventually freed off. Don't seem to be getting anywhere here.

[Zebster]

Not a volvo, but when I had to remove the diesel injectors from my Honda Accord I gave them a good overnight soaking in WD-40, then started the engine and - very carefully and at arms length - slowly loosened the clamp bolt just until I saw bubbling from each seat. I managed to do this in less than a minute and they all came out easily after that.

Or instead you could hire/improvise a slide hammer?

[SwissXC90]

Decent garages have proper injector removal tools for difficult injectors.
These involve slide hammers and many other trick tools.

But even then sometimes the injector can be damaged...

[NMB]

Originally Posted by realslimshady

Alongside my current 'oil leak' thread, I have identified the leak but am now stuck as to remove and reseal the black plastic rocker cover I need to remove the injectors, and they are call seized solid.
I have been plying them with WD40 and then Liqui Moly super-duper unseizing agent for 10 days or so, but I still can't budge them.
Just tried putting a blowlamp onto one but the plastic is too close and starts melting.
So. Any tips? I had the same with one on my Voyager but after lots of dousing and wiggling that eventually freed off. Don't seem to be getting anywhere here.

Excellent idea about using the engines comprssion to lift the injectors.

Re WD 40 - i have bought a product called Seafoam penetration fluid and beleive me this stuff gets in anywhere - it's far better than WD40 and i couldnt recommend it more.

[realslimshady]

starting the engine not an option as had to strip loads of it to get to where I am. I did think about it, but when considering the area of the injector actually exposed to the compression in the cylinder-basically the nozzle-didn't think it would be that effective.
However, I am now considering how much I can get away with not refitting to get it running so I can get it hot which may help....
I have also ordered a slide hammer-type removal tool.

[laundryman]

The easiest way is slide hammer. on ebay at reasonable cost. flat bladed driver to remove the copper washers. on reassembly DO NOT put any grease on the washer or injector. make sure they are dry and clean.

[realslimshady]

well. I put back all the bits needed to start the engine, which did, after a bit of encouragement, and I ran it up to temperature a couple of times and squirted more magic stuff around. Then removed fuel pipes from 4&5 and had another go at freeing them, no joy.
So this morning the slide hammer tool arrived. Tried it on #5, no joy, so I thought I'd run the engine to temperature and see if that helped.
Except. The bastard won't start. Just doesn't seem to be any fuel pressure. Cracked the pipes here and there and when cranking fuel is coming out, but with everything tight there is no combustion and no 'spray' after trying to start. Getting slightly annoyed.

[XJSDriver]

Si Robb has produced a great video on removing a seized injector https://www.youtube.com/watch?v=NL8JI10Du18

Not sure what you mean by 'no spray' after start if you have tightened everything down; you could still have an air in the system so need to bleed it a bit more - I believe the Volvos self prime by turning the ignition on and off a few times; you could try that and hopefully eventually will start.

[realslimshady]

Originally Posted by XJSDriver

Si Robb has produced a great video on removing a seized injector https://www.youtube.com/watch?v=NL8JI10Du18

Not sure what you mean by 'no spray' after start if you have tightened everything down; you could still have an air in the system so need to bleed it a bit more - I believe the Volvos self prime by turning the ignition on and off a few times; you could try that and hopefully eventually will start.

I meant there was no residual pressure. Anyway.Fixed it. But. Can NOT remove the injectors, even with a slide hammer.
So I'm botching it back together with some sealant injected in the gap available under the rocker cover and hoping I've improved it (the oil leak that is).

[realslimshady]

So. Unfortunately, while the botching fixed the original oil leak quite successfully, the disturbing of the rocker cover/inlet manifold has produced leaks around at least two of the injectors, as well as various other places. Not exactly unexpected.
Which means the injectors HAVE to come out.
Into the garden this afternoon after a two hour run, got the slide hammer on them while the engine was still piping hot, and managed to get two out. One came fairly easily (#4) and #3 needed hammering all the way. But the other three are still solid. Bearing in mind I have been dosing them in penetrating oil (and engine oil involuntarily) for the last three weeks or so.
I am putting every ounce of effort into the hammer, and I'm not a small guy.
I am hoping a younger, larger, stronger acquaintance will come round and have a try, but it's getting silly. And my hand hurts now...