Engine: 70 T5: Injectors stuck in manifold

[Distendo]

'98 V70 T5

Removed two bolts and clip from fuel rail, but can't pull injectors from manifold.

Don't want to get too violent. Have been squirting carb cleaner onto them in hopes of dissolving built-up gunge on seals. I can wobble rail and injectors back and forth, but no joy yet on pulling them out.

Injectors appear to be secured to fuel rail by a thin metal plate fixed by three screws. I'm thinking of trying to remove screws and so the plate in hopes of removing rail (seals in it may be less solid and gunged-in than manifold seals) and so be able to twist injectors in manifold seats.

I don't mind ruining the seals as I'll replace those anyway.

Any bright ideas?

Thanks

[SteveSarre]

Hi

Yes I would remove the screws and then the plate and see if you can then work them out.
Then replace with new seals.

Steve

[SteveSarre]

The standard way, if they are not stuck is shown here

https://www.pelicanparts.com/techart...eplacement.htm

Steve

[Distendo]

Thanks for the contribution, Steve.

Believe me, before embarking on this process, I did my research, including the page you mentioned. It's just that there isn't so much on what to do when you've bent the biggest screwdriver you have trying to lever the fuel rail & jets off.

I'm still squirting the carb cleaner on the jets and penetrating oil on those screws, and will have another bash (so to speak) tomorrow. I'll post the results just in case anyone else comes across this prob.

Cheers.

[Distendo]

Ok, so I bought a small ratchet spanner for hex driver bits, and a set of torx bits, cut down the T25 bit to shorten it so it would fit in the confined space between head and fuel rail, and removed the 3 screws that fix the plate which holds the injectors in place in the rail (which came out surprisingly easily).

I was then able to lift the fuel rail from the top of the injectors.

One injector was already free of the manifold (I assume blown out by pressure from within the duff cylinder), but left the copper sealing washer (below the O ring seal) in place in the manifold. Obviously it's those washers which are stuck in place and preventing the other injectors from coming out, but for now I'm leaving the remaining 4 injectors in place in the manifold.

I have spare injectors now (ebay), so I'm planning on freeing up the stuck washer which I reckon, given how tight they are, may get damaged in the process, and probably replace it, either with a complete spare inj., or if the washer's ok, the original inj. with a new seal.

I haven't been able to find spare injector washers (can find seals, but not washers), so anyone any ideas there (or a part number)?

Also, I may try to free the other injectors from inside the manifold once its off, but the nozzle end of the injectors looks very fragile, so bashing away near it is probably not such a good idea. Any other ideas, anyone?

[SteveSarre]

Hi Distendo,

I suggest getting part number and prices for the washers (and other parts) from a Volvo dealer.
Then buy them or shop around.

They should be able to get that info from your VIN.

Steve

[SteveSarre]

Hi Distendo,

I don't know your precise situation and haven't encountered that problem before, but if you have spare injectors, can you not simply use vice grips to twist the injectors out of the manifold?

Or even replace with a good used manifold? (Various versions so be careful to get an exact match). Look for a part number. Not that difficult to change over.

What spec and year do you have? (OK I see now '98 V70 T5).

If you do take the manifold off, that would be a good time to change the PCV tank and hoses that live below it. And do vacuum hoses too.

Steve

[Distendo]

Hi, thanks for the continued interest!

The injectors twist round but are firmly stuck. I have the manifold off now, and can see the washers at the nozzle end. I reckon I may be able to use a small screwdriver from inside the manifold to free the washer left behind (from when the one injector popped out pre-dismantling), but don't fancy having a go at the others without some sort of cleaning up solvent first.

I've been looking at this 'Injector Dismantling Aid Pro-Line':
http://www.skandix.de/en/spare-parts...00-ml/1060549/
with a view to applying it from inside the manifold (the O ring stops anything applied from outside) but want to make sure it won't mess up the injector nozzles, so I'm making enquiries.

On the other hand, I could just leave them in place... And either use one of those spares to replace the original that's out, or, if I can replace the washer, put that one back. I'd replace the seals at the fuel rail end at least.

I have a PCV kit ready to go, but will check out the other hoses. Some are certainly looking a bit old. That's a layer of complication I'll save 'till I have the cylinder head off and have made sure it's only an exhaust valve that's gone.

All good clean fun...

Cheers!

[Distendo]

Turns out those o ring 'washers', or retainers, are 'pintle' caps. seems the o ring can be removed and refitted over them, as removing the pintle cap can break it.

I (think I) saw them described as made of copper. The one I can see in the manifold looks like that, but my spare injectors have plastic ones, in white (and one is brown).

Can't find them for sale anywhere...

[SteveSarre]

I think that you will find that Skandix charges quite a lot for delivery.

Steve