Fuel Injectors stuck in head.... any suggestions?

I have 3 of the 10 injectors not wanting to budge. Number 10 has had it’s plastic pulling collar disintegrate using the special puller tool, number 1 has one side cracked and the number 6 is intact. I had sprayed some PB blaster on them a few hours before the attempt.

The #1 side cracked was my first injector and I wasn’t paying attention, or rather I thought the creaking sounds were the injector walking itself out… I should have been looking at the injector more closely. You can barely see the crack in the photo, but it’s there:

The #10 surprised me since I was being very careful and thought I had not put that much torque on it. The others came out hard, but with no damage, I was very careful after #1’s failed attempt.

So, grab it with vise grips? Heat? Something else? I do NOT want to add a head gasket and redo of the cam girdles to my budget, so whatever I do, those three injectors need to come out cleanly. If all three are toast (as I think 2 already are) so be it. I’ll eat the $500 bucks rather than go backward on the work.

Rest are ready to hit the ultrasonic cleaner once my injector tester gets here.

Without that plastic collar, my guess is that the metal holders will not work, so I am out at least 2 injectors right now (and man they are expensive).

All BTDT’s are welcome and appreciated.

The

Well I went to check them again and they seemed to be moving back & forth & turning a little easier.

I got #10 (which I thought was going to be worse) and #6 (undamaged) out. Unfortunately whenI was doing the same to #1, while it was moving and behaving like the others, in reality it was not. The lower section is now stuck in the injector tube. I can see this:

I have some taps I could try, or I could try and drill into the remaining collar and see if I can grab that. I dissected one of the trashed injectors and the remains are the circular dish you can see, and a now empty tube terminating in a tiny spray hole.

There isn’t much room around the outside of the dish to grab, medium needle nose can make it, but it does not budge. Thinking I could us something to grab the inside edge, I had a set of the bits that are designed to help you remove plumbing pipe, but the smallest is too large.

I am leaning toward drilling and tapping, the shavings should be caught by the nozzle at the bottom of the tube, but I would like to grab it somehow to rotate it. Maybe a reverse snap ring pliers or something.

I am also thinking of heating the shit out of it first to see if I can break its grip.

So close…

Ed

I was faced with the same situation about four years ago. I drilled and tapped the injector, threaded a bolt in and then used the injector puller to remove it.

OK, then I am on the right track, what a PITA. I am calling it a night.

Do you remember what size tap you used?

Ed

All I recall is that I used an inverted 3/8" drive socket to capture the head of the bolt in the puller.

Got it. Nice idea. It’s amazing what you have to, or can, do to get out of situations.

Ed

I have been at this off and on for the better part of a day with 2 Milwaukee Cobalt hard metal bits and I barely have a bevel started in the center hole.

Do I need to spend $20 on a solid carbide tip?

I have also cut a couple of slots into the top of this what appears to be hardened stainless and used a couple of large screwdrivers (after more PB blaster) to get it to rotate and it is just not budging.

If I need a solid carbide drill bit then I probably need something a bit better than the taps I have (though I forget where I got the extra M5X1’s I have).

I guess the moral of the story is pop out your injectors every 75K miles or so (unless they have some kind of anti seize for injectors that’s safe for DFI engines.

I’m waiting on the RMS tool anyway, but this is starting to annoy me.

Ed

I went with a relatively slow drill rpm and probably stepped up through four drill sizes to get it to the size for the tap.

Eng, thank you very much for the inspirational words of wisdom.

3 step ups in bits, the removal of that spinny thing with holes in it, tap, screw and use both the hammer (to get it started) and the screw puller and the F’n thing is out (without removing the dang head):

Now back to my regularly scheduled program (actually that involves a couple of double IPA’s)

Jeez that was a lot of work.

Ed

Question: When re-inserting the fuel injectors should I use something like this:

Liqui Moly Pro Line Injector Grease

Ed