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Discussion Starter #1
My camper has an ACV lump and I want to renew the injectors as it's done 140+k miles and I've got hold of some brand new VW ones with larger nozzles (.203s) so I can get a bit more power and mpg with another tweak to the map (Martin at Pendle did a nice job soon after I got it 18 months ago).
So I try changing the injectors and find they are well and truly stuck in the head. The high pressure fuel lines are well rusty but I managed to get all the union nuts cracked off without breaking any, but so far I have only managed to get one injector out. I got hold of a new connector nut from my friendly local diesel specialist so I could use that to twist the injector once I removed the fork-clamp. This worked with the one furthest left - I started with that cos it's got best access by partially dismounting the radiator. I've then tired the next and the next but they won't budge ( I soaked them all in penetrating fluid for hours beforehand). I've also tried a large slide hammer but can't get it quite in line so not as effective as it should be I suppose - still managed to shear off a bolt I used to link the union to the slide hammer, tho.
So what next?? Any ideas??
 

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Hi

I used a home made slide hammer.

I used a s/h 2.4 head bolt and a s/h 2.4 gudeon pin then welded a M14 fine nut to a M12 nut .

The gudeon pin is slid onto the head bolt then the bolt is screwed into the m12 side of the joined nut (I used another M12 nut to lock the bolt to the nut) the M14 fine nut can be screwed to the end of the injector and the whole lot will fit inbehind the tipped forward radiator. and just use it like a normal slide hammer.

Works every time for me.

I have some extra welded nuts if you want to try it.

Cheers Trev.
 

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Anyone know if these pullers can be used with the rad just moved up and onto the bumper?
I have one of these they work well.

A couple of tips:

Pour coke (yes coca-cola) around the injector holes and leave overnight - has to be the real stuff - the cheaper varieties weren't as effective - for me anyway :D.

Make sure the engine is stone cold when you try to remove the injectors

Do not twist the injectors anti clockwise when extracting them :eek:

Good luck
 

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Discussion Starter #5
Thanks for that Trev.

I did think of trying to make a small puller for this but don't have a small weight that would do. Or a head bolt long enough either come to think about - hence thinking of buying a proper tool; £35 isn't that bad if it does the job but then I wouldn't use it for years!

Anyone know if these little slide hammers fit in the space??
 

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Discussion Starter #6
Penbryn
Thanks for that - just the info I needed!
I'd heard about the coke thing but hadn't tried it yet.
Maybe I'll get one of those pullers then...
I'll let you know how I get on next weekend.
Once again - diolch yn fawr
 

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Penbryn
Thanks for that - just the info I needed!
I'd heard about the coke thing but hadn't tried it yet.
Maybe I'll get one of those pullers then...
I'll let you know how I get on next weekend.
Once again - diolch yn fawr
Croeso! I paid £25 for mine on fleabay - I'll see if I can find the link for you. You may need to move the rad out of the way to get at things properly though...
 

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Discussion Starter #9 (Edited)
Nice deal! You are better at finding bargains on that place than I seem to be. The cheapest I found was £30+4 and went for it this afternoon but whatever!
re the radiator - I dropped it gently off the hinges and disconnected the plug at the left end but that still left a medium size hose attached - not too sure what it is, maybe steering? Can't see an easy way to disconnect this - crimped ends... or am I being a wuss and it's ok...
 

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Nice deal! You are better at finding bargains on that place than I seem to be. The cheapest I found was £30+4 and went for it this afternoon but whatever!
re the radiator - I dropped it gently off the hinges and disconnected the plug at the left end but that still left a medium size hose attached - not too sure what it is, maybe steering? Can't see an easy way to disconnect this - crimped ends... or am I being a wuss and it's ok...
Sounds like PAS cooler - cut the crimped hose clips if you like and reattach using jubilee clips afterwards. You may need to bleed the power steering having done this - but that's no big deal T: and getting the rad right out of the way really makes the job easier. HTH
 

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Discussion Starter #12
I'm waiting for the extractor kit to arrive so haven't touched it again, other than to measure the clamp bolts so I could get some new ones. The existing ones are well rusty and getting a bit mangled by my hammering the allen bit into them - the new ones have arrived today and I've also checked out the steering pump hose etc so I can get the rad out of the way.
Hope to get to it on the weekend. I'll keep you posted...
 

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Discussion Starter #13
Had another go at this today and cracked it! Well pleased!
Getting the rad out of the way and having the proper tool to pull them out was the two key things I reckon. And they still needed a lot of pulling to get em out.
Just need to see if it needs another remap now. Not much smoke but I only went round the block so not a proper test. Away this weekend so that should tell me more.
 

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Chaps,
I remember doin a lot of cursing trying to get my old injectors out.
Eventually found a budget techinque...
Once you've removed the forked-clamp, wind a nut on top of the injectors and tighten til the injector spins once, then it's an easy job extracting them.
Cheers,
Phil.
 

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Discussion Starter #15
Yeah Phil - nice idea but I tried that and they didn't move.... may work for some I spose

Anyway my new injectors seem to be doing the business. Engine is nice and full of umph!
Now got to decide when/if to get another tweak to the map. There doesn't seem to be much smoke but still early days.
 
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