I have a crusher washer stuck in an injector hole.
Any ideas?
Tried grease on the base of the injector. Wire brush. Metal dental picks.
I think it's like fused in there!?

Get the shotgun cleaning kit from Walmart. Use the narrow copper bristled brush, it will fit down the center injector hole through the crush washer. Twist it as you are shoving it through, and the washer should jam on the brush and come right out.

Then use the wool soft brush (mop) drowned in brake cleaner to clean the injector bores. You cannot use too much brake cleaner.

Thanks. Hopefully they have that kit in Canadian Walmart. Will look tomorrow

i have injector seat cutter tool 17x19 mm ,from princess auto store , works well ,

Blast of compressed air.


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2005 Jeep Liberty CRD Limited
Build Date May '05
OME lift kit
Samco hoses
Weeks Stage 1
PMF EGR plug kit
ARP Stud
Cracked CAC repaired with epoxy filler

Geez 2 days and still not out. I am starting to hate this motor!
Tried blasting air. Got a shotgun cleaning kit that didn't work.
It's really in there.
Princess auto discontinued the injector seat cleaner so that's a no go.

you must find the injector cutter tool on Amazon, or if you're near Toronto area i could lend you mine.

Soak for a couple of days of repeat applications of PB Blaster or something similar then retry bore brush tip or bent dental pick. I'm not sure I should mention this as it's risky but if you have access to wire gauge drill bits perhaps you can find one just large enough to catch the edge of the washer but be careful not to drop it into combustion chamber or damage threads (if a long wood screw could be found in the right size that might work too).

Having a washer stuck in there seems extremely odd. Not to doubt you but are you positive that's the case? I ask because the OEM crush washers have tiny teeth on the inner edge that tightly grip the injector to the point that I don't see how one of those washers could avoid coming out. I suppose that could happen if a) someone used just a regular copper crush washer instead of OEM and/or b) the washer did not adequately seal the injector bore in which case it would be all cruded up with diesel "stuff" that hopefully PB Blaster will dissolve.

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Why not just take a long lag bolt and catch the washer and pull it out?

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Proudly supporting CRD vendors, and their development of quality parts and accessories.
Equipped with HDS thermostat, plenty of heat, faster warm-ups, increased fuel mileage.

So if this thing is in there so good. What would happen if I just used a new washer and left it in?
Do you think it would seal?

Of course this is injector 4 the hardest to reach...

I thought about this but I am concerned it might mess up the injector tip bore

Unlikely - the ONLY sealing surface is the flat seat under the crush washer. The hole into the cylinder is just a passage for the injector tip. So unless you are carving away at the aluminum with that screw, the copper should be the first thing to give way.

The aluminum can take a bit of scoring or damage here, but don't go crazy. I'm surprised that a pick can't get at it either.

To get visibility in there, you may find it helpful to deflate the front tires. You will gain about 4 inches of reach / stretch across the lowered engine.

dont damage cylinder head , ! you need a tool , call me 905 763 5814 Ranko

Well the taper of the lag is going to catch the copper before the aluminum, use a 5/16 or 3/8, not something as small as the injector tip.

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2006 LTD Bright Silver loaded with all the needed mods, CCV intact.
Proudly supporting CRD vendors, and their development of quality parts and accessories.
Equipped with HDS thermostat, plenty of heat, faster warm-ups, increased fuel mileage.

I would try using a long tapered punch or hole alignment tool. As you push the tool into the washer it should wedge onto the tool and rock it back and forth to break it loose. Should be able to pull it right out. It worked for me.

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2006 Liberty CRD 275K, JBA 2.5 with Fox Shocks, GDE Turbo Kit, GDE TCM Tune, Suncoast TC, OEM fuel filter housing converted to fit Caterpillar Fuel Filter 1R-0749, OEM themostat housing modified to accept Hemi 203 F thermostat.

he has my injector cup cutter tool , he is cutting slowly thru this copper washer .please be patient

Do you think the debris will pose a threat to the combustion chamber?

I had a stuck one on #4 also. I used a big flat head screwdriver that had enough taper to grab the washer, and not touch the bore. PB blaster, bought a 90 degree drill to fit back there, and the shotgun brush, and then it finally loosened up.

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Mech fan, VH & AC delete

It's copper, so it would be a lot softer than anything else in the combustion chamber other than the fuel... But I would still make a suggestion: Pull the #4 glow plug while you have the opportunity and run shop air into that while you have a shop vac sucking from above on the injector bore. This will clear anything that might be on the top of the piston right out. Use a fat rubber tip on the blowgun to ensure that the air can ONLY enter the cylinder that way, and only exit from the top.

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This is a good idea but its to late lol.

The tool worked! I didn't have to dig right through the washer after a couple tries it came loose.
Got her all back together and runs okay.
starts with a big rev then goes to normal idle. there is also a hesitation if I hold the idle around 2kish rpm.

Gonna but it all back together to see if that helps.

Ranko you are the man! Thanks so much for the tool.