Broken Fuel Return tip in Injector

TKB4 · **Posted:** Tue Aug 06, 2019 12:57 pm

Any ideas on how to get the tip of the fuel return plastic piece out of an injector without damaging it and without disassembling it ? I tried a pick tool didn't work. I am sure I could break it in pieces with something like a small screw driver but am concerned it may damage the injector. Thought also about carefully threading an extractor into center or even a drill bit or screw and see if it will pull output haven't tried that yet. I don't think heating it with blower would be of much benefit since it is designed to be in hot area. Here is a pic:

https://imgur.com/UVdKJPJ

Suggestions?

Steve777 · **Joined:** Fri Oct 16, 2015 11:31 pm **Posts:** 279

Haven't had to deal with this (yet). But I'd probably try drilling the plastic out, a little bit at a time. Likely would use a pin vice or other hand chuck, so that no machine turning the drill bit and going too far, and likely try holding it upside down so the pieces fall out. Would be slower, but this is only plastic so shouldn't be that hard or take too long. Once most of the plastic is out might be able to collapse the remaining shell, or use a knife from the inside to slit it. No guarantees, but seems like it should work.

Steve777 · **Joined:** Fri Oct 16, 2015 11:31 pm **Posts:** 279

Haven't had to deal with this (yet). But I'd probably try drilling the plastic out, a little bit at a time. Likely would use a pin vice or other hand chuck, so that no machine turning the drill bit and going too far, and likely try holding it upside down so the pieces fall out. Would be slower, but this is only plastic so shouldn't be that hard or take too long. Once most of the plastic is out might be able to collapse the remaining shell, or use a knife from the inside to slit it.

Also possible the remnant will "stick" to a drill bit, in which case you could pull it out.

No guarantees, but seems like it should work.

TheKansasGman · **Joined:** Fri Jun 07, 2019 10:02 pm **Posts:** 39

Get a knife (or wire?) red hot and use it to slice it into two or more pieces. Remove with gravity.

Garrett

TKB4 · **Posted:** Wed Aug 07, 2019 11:53 pm

maybe small wire red hot but could also melt it in place I guess.

GordnadoCRD · **Posted:** Thu Aug 08, 2019 4:01 am

Send it off for service?

https://oregonfuelinjection.com/services-repair/fuel-injector-rebuilds-testing/

geordi · **Posted:** Thu Aug 08, 2019 3:38 pm

Dealt with this plenty of times. You need a small wood screw, I usually use a fine-thread drywall screw. Turn it in by hand into the plastic just a bit and it will break it free and pull it right out.

The fuel line is available from IDparts but also available at your local auto store if you ask them for a single bank return line from a 2005 Chevy 2500 pickup with the Duramax V-8. Should be about $30.

TKB4 · **Posted:** Thu Aug 08, 2019 10:59 pm

I did this today and it did work. I took line apart toward return block from number 4 injector and left the last several inches attached to the block with the connector so i didn't have to remove and replace as much stuff but I used the line from my salvage jeep back to the same junction.

Thanks, I guess great minds think alike :BINGO:

Broken Fuel Return tip in Injector

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