Injector Removal: A Hard Case

Hi,

I'm having a huge problem. I can't get one of the fuel injectors out (the other three came out easily).

Golf III AFN 3. Cylinder.

I tried it the gentle way: using a rust remover and gently wiggling it. Only the top part came loose from the bottom.
I tried it with a sledgehammer, approximately 8 kg in weight. The threads on the adapter nut I used broke.
I've tried it the really bad way (and I'm still trying): Just go for it, full throttle.

Result: Not even a millimeter has the nozzle moved! That can't be right. It's just plugged in!

Does anyone have any other ideas before I remove the cylinder head and push out that blasted injector?

Is there a device that allows you to pull the nozzles upwards by supporting them against the head?

I don't know what to do next.

Varianti wrote:

Hi, I'm having a huge problem. I can't get one of the fuel injectors out (the other three came out easily). Golf III AFN 3. Cylinder. I tried it the gentle way: using a rust remover and gently wiggling it. Only the top part came loose from the bottom. I tried it with a sledgehammer, approximately 8 kg in weight. The threads on the adapter nut I used broke. I've tried it the really bad way (and I'm still trying): Just go for it, full throttle. Result: Not even a millimeter has the nozzle moved! That can't be right. It's just plugged in! Does anyone have any other ideas before I remove the cylinder head and push out that blasted injector? Is there a device that allows you to pull the nozzles upwards by supporting them against the head? I don't know what to do anymore.

As far as I remember, there's a flattened area on the bottom where a 15mm wrench fits. You can use that to rotate the nozzle about 10 degrees to the right and left. Eventually, it will give way...
Otherwise, the only thing I know about is the issue with the striking weight.

Hello,

Have you tried heating it up (really hot)? The nozzle has to come out anyway, so try shielding the rest of the head and the wiring from the heat with some old pieces of metal, and then see if you can get the nozzle to glow.

Best regards, Rainer.

@Bertil:
The nozzle is split into two parts. The wobbling caused only the upper part to detach from the lower part. If I turn the nozzle further to the left now, I'll have the upper part of the nozzle in my hand, and the lower part will be stuck in the head. This has happened to me before with my 1Z engine. Somehow, it always seems to happen with my engines. Many other nozzles came out without any problems.

@Rainer:
Are you saying that the burner is used to heat the nozzle? I'm not a welder, but I imagine that by the time it gets hot enough to glow, the metal would have already melted, right? I don't really have a good understanding of how that works.

Hi,

Varianti wrote:

Are you saying that a burner is used to heat the nozzle? I'm not a welder, but by the time it glows, wouldn't my head have melted, or something? I don't really have a good idea about that.

Well, before that, one should already stop .
It's definitely worth a try; if you use a soldering torch instead of a welding torch, nothing should melt.

Best regards, Rainer.

I'm going to give it a try. But first, I want to spend some more time driving on the highway today.

I simply can't imagine that a fixed nozzle would remain in place inside the cylinder when there's 200 bar of pressure. It's practically impossible.

Are you continuing to inject fuel into the cylinder, or are you letting it run empty?

If the former is the case, I would be very concerned that a lot more could break if the thing actually comes out, and if the latter, then there would only be about 30 bar left, not 200.

Best regards,

Jan.