#4 Injector Removal

ZACH · **Posted:** Sat Jul 05, 2014 9:04 am

I have tried everything I can think of to get the injector out, I have had it soaked in PB Blaster over night, tried coke too. I built a couple versions of pullers. One with bolts on each side with a notch between to grab the injector. One with a pry bar over the injector, I start lifting the weight off the suspension with this and it still won't budge. I can get it to twist about a 1/4 to 1/2 turn back and forth, but it won't come up any. I can't try running it a little because I have the timing belt off.

I am going to try to build some kind of slide hammer contraption next. If anyone has any ideas please let me know.

05 Liberty 2.8 CRD with 150k miles.

thermorex · **Posted:** Sat Jul 05, 2014 10:04 am

If things get so desperate, I'd use an impact in short bursts, but than can ruin the injector and head seat...

ZACH · **Posted:** Sat Jul 05, 2014 11:15 am

How do I get on it with an impact? Cut the socket to fit around the electrical connector? If so what size socket?

Yes, things are getting desperate, I have about 22 hours into trying to get this one injector out!

jrsavoie · **Posted:** Sat Jul 05, 2014 11:32 am

I have nothing much to offer other than I have found that plugging the block heater before working on things helps things move a little easier.

I do not know exactly how all that goes together but it sounds like a galled thread issue to me.

Is there a way to heat the injector & spray some Sea Foam on it? I have had my best luck with heating and removing with SEA Foam in a pump bottle or Sea Foam Deep Creep - aerosol.

Another good example of why people should use a good high temp anti-seez and proper torque specs

diesel_guy86 · **Posted:** Sat Jul 05, 2014 3:21 pm

These injectors don't thread in like the old 80's diesels. The fall down into the hole and is held in place by a piece known as a crows foot. There is a copper washer at the very tip of the injector, and an boring farther up that keeps dirt/ moisture etc out. Soot can leakbpast the copper washer and glue the injector to the aluminum head. If the boring is still good, you won't be able to get any solvent down into where its needed.
I think I would first try to get the injector to spin all the way around to help break it loose, see if you can pull it up till it gets tight, and then twist it more, it might take 2 people to do it.

thermorex · **Posted:** Sat Jul 05, 2014 3:50 pm

ZACH wrote:

How do I get on it with an impact? Cut the socket to fit around the electrical connector? If so what size socket?

Yes, things are getting desperate, I have about 22 hours into trying to get this one injector out!

I am not sure if that electric connector comes out from the injector easy, nor how steps need to be followed, some injector sockets for some cars have a hole in them (like Mercedes, Audi and vw) not sure if that would fit... Sorry, no better ideas from me.

ZACH · **Posted:** Sat Jul 05, 2014 4:46 pm

Can't spin it all the way around, the part were the fuel line connects hits the valve/cam cover.

I have the electrical connector off now, don't care about the injector anymore, just trying to get it out.

WolverineFW · **Posted:** Sat Jul 05, 2014 4:50 pm

If you have given up on the injector, I would get a heat gun, not a torch, and heat the metal body of the injector up. Might want to wrap the plastic plug in a strip of wet rag. You might be able to work it loose then.

ZACH · **Posted:** Sat Jul 05, 2014 5:15 pm

Anyone want to buy it? I am pretty sure there is a broken rocker arm. I have all the parts to fix except a new injector. Full set of rocker arms, timing belt kit, new Samco hoses, etc. All from IDparts.

Seriously.

I will get some pictures and a more detailed description up in the for sale section later tonight.

I am going to keep trying to get this thing out, but that is how desperate things are getting.

Mike92104 · **Posted:** Sat Jul 05, 2014 7:32 pm

Using one of these as a lever:

http://www.harborfreight.com/16-inch-ti ... -1759.html

Wiggle the injector back and forth (not spinning) while using the tie rod tool as a lever to force the injector up. If you play around a bit with the tie rod tool, you'll find a place to grab the injector with the fork, and a sweet spot on the manifold to use as a fulcrum. Wiggling has helped several people get the injectors out.

Mike

ZACH · **Posted:** Sat Jul 05, 2014 8:06 pm

Yup, tried that. Won't budge.

Thanks though, any and all ideas are welcome.

diesel_guy86 · **Posted:** Sat Jul 05, 2014 8:52 pm

If your desperate, shove some c4 through the intake valve, boom injector problems gone.

ZACH · **Posted:** Sun Jul 06, 2014 7:43 pm

That might work, but unfortunately I don't have any C4.

http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=35&t=79542

minisub · **Posted:** Mon Jul 07, 2014 9:46 pm

Do you have a bearing separator? You might be able to get enought bite on the top of the injector to apply some upward force with no hands and then apply some vibration with an impact hammer backed up with a dolly. The hockey puck, wiring harness and height of the valve cover will make this tough, but looking in the engine bay of mine and my tool box tonight, that would be something I would try myself.

Best of luck. You have the skills and confidence to tear into this and do the rocker job, don't dump the whole truck now!

Another idea, since I am convinced that these cases of "mechanical" adhesion, for lack of a better term, require both tension and motion, would be to use a wire cable clamp, wire rope or chain and a gantry of some sort with a way to apply upward pressure with the aforementioned impact hammer for the motion part.

thermorex · **Posted:** Mon Jul 07, 2014 9:55 pm

I wonder how a slide hammer can be attached on the troublesome injector...

ZACH · **Posted:** Mon Jul 07, 2014 10:19 pm

Thanks for the ideas, I will continue trying things until the injector comes out or the Jeep is gone, whichever comes first.

It is in a really tough spot to get anything on it, and because it is #4 it is at the back and is more or less under the windshield, can't really get a slide hammer thing to work.

Maybe tomorrow I'll post some pictures of the "tools" I have tried so far. My homemade ones are pretty special looking.

thermorex · **Posted:** Tue Jul 08, 2014 7:44 am

Zach, did you try a lock channel pliers, like the biggest you can get? I was able to hold rounded rusty bolts with those, while using an impact on the nut, I think it would worth a try. If that doesn't work, maybe a huge, heavy duty pipe pliers, like this:

http://www.harborfreight.com/36-inch-st ... -1132.html

I'd also remove the fuel rail and all the fuel lines (if you haven't already - the pics you posted don't show those removed), the ccv puck and the cam sensor, that would give more space to play with those big boys.

ZACH · **Posted:** Wed Jul 09, 2014 8:53 pm

I have tried pliers (not a pipe wrench yet), but the problem is not getting it to spin, but getting it to slide up and out. I have spun it in both directions, I can't spin it all the way around because the part where the fuel line connects hits the exhaust side of the cover.

Here are some pictures of the "tool" I made, essentially a 1/2" wrench welded to some plate which pivots on a bolt through a pipe, I was pushing up on it with the end pressing on a socket placed on one of the cover bolts in back. Either I would have someone else use a pry bar to hold the "tool" on the injector, or I had hose clamps around it and the injector holding them together.

diesel_guy86 · **Posted:** Wed Jul 09, 2014 9:23 pm

It's hard to believe it'll twist, but won't come out, makes me wonder if the tip is damaged, or has built up crud on it? Have you tried taking the valve cover off? It might clear the injector since you have the solenoid part off. If you can get that off I'd take the head off and go at it from the other way. Worst case you destroy the nozzle and need a new one.

ZACH · **Posted:** Thu Jul 10, 2014 7:22 am

I don't think the cover will clear the injector because of the part where the fuel line connects, but I'll take a look at it tonight.
I'm pretty sure the injector will need to be replaced anyway so if the cover will come off then I'll try it that way.

#4 Injector Removal

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