OK so i am pulling my last 2 injectors this afternoon with the slide hammer method. Cylinder #3 very,very stubborn. I have now slid all the threads off the injector . Its really stuck, i have been trying a set of vise grips on the end of a slide hammer but after 3-4 hits they pop off and I have to reset them. I spray a ton more penetrating oil and move on. Cylinder #6 slide hammer is to long so I make a new shaft and presto the injector pops out but I look at it and the tip is still in the head. So what do you guys think. I am not sure what to do for either cylinder now. Any suggestions?

 

I think it might be time for Begle1's method.

I never heard of the tip sticking in the head. I'd suggest an ez-out - at least to give you something to hold onto so the tip doesn't fall in the cylinder once you break it free. I have no expreience with this sort of nightmare (thank God) so I suggest you wait for other opinions.

 

Is it posible that you could take the o-ring of from the injector, lube it up good and try to spin or twist the injector back on to the tip and the try to pull it out again?

 

WOW!!! Finally got cylinder #3 injector out.(bore is almost completley full of carbon deposits) Hit the slide hammer with every thing I had at least 20-30 times in a row non stop while sitting in the engine bay. Tightened the visegrips onto the injector with another pair of visegrips. So that just leaves cylinder #6 with the tip in the head. I am not sure how removing the o-ring(I assume you mean the split ring near the tit on injector) will help. I think the problem will be the tit not wanting to move past the notch in the bore. I am contimplating grinding off the tit and trying to rethread the body onto the tip but the threads already let go once so they may not be strong enogh to hold on any way.

 

I haven't removed a 1st gen inj (yet!) but can only pitcher how thay are.

Fig the tip must be threaded on to the end of the injector. Maybe had vibrated loose or hadn't been tight in the first place, before you remove them and you could just thread it back in all the way and them pull it out.

 

I know it's a lot of work but...
If it comes down to it remove the head and punch it out from behind.

 

My method wouldn't have broken the injector in the first place...

And you are going to take the head off anyways to get it ported and O-ringed, right? (Just keep telling yourself that...)

 

Put a old pillow the wife dont know she doesnt need over the injector and spin it over, if it dont come out put the other 5 in crank it , it come out.

PS i do stupid things but i get the job done

 

ground off the tit on the injector from cylinder #3(it was beat up anyway) and spun it on the tip. Hit it with the slide hammer a dozen times and POP. Looked at the vise grips and pulled the body from the tip again. Ground the tit off another body and put red loc tight on it this time. I spun it onto the tip and am now letting it sit so it dries. I wish I could try the spin the engine over method but I have no injectors hooked up and the turbo/exaust/crossover is all removed for the new parts.

 

just have some one hold the manual fuel lever,or you could just let the inj dribble fuel(without it being hocked up to the inj there will be no pressure in the lines?)

just leave the lines off an crank it over, the compression of the piston will put around 400 psi in the syliner ....it could work!

 

Well after almost 7 hours that injector #6 is finally out. Out of ideas, about to start pullin the head I think lets try that new deburring bit. I carefully start removing metal from the lower body the tip is sitting in.(its still in the head) I was using a magnet pencil to remove shavings as I went and after removing much material from the body and tip the tip finally comes out on the magnet. This just leaves the body in the bore. The body is just mild steel so I grab an easy-out and start twisting. After some effort the body began to spin in the bore. I put my visegrip/slide hammer on the easy-out and the body finally let go. I hope no one else has to deal with injectors like these. What a headache. Anyway I have some parts to install thanks for the ideas guys.

 

Next time just put a heavy blanket, pillow or canvas over the offending injector and crank the motor over. Spinning over on the starter makes more than enough pressure to pop it out(pull the wire off the fuel shut off selonid in case in does start). You don't actaully want it to start. Just be sure to stand well clear. People have been killed by injectors punching holes in their chests, mostly on large marine applications.

 

I had tried to the crank the motor over method before my last go-round. Injector didnt move a bit. Probably cranked it a total f 2-3 minutes at different intervals allowing the starter to cool. Didnt do a darn thing. Keep in mind I was using a 8lb(aprox) slide hammer with every once of stregth I had for 4-5min non stop at a time and the injectors would not budge. They were VERY stuck with lots of carbon build up.

 

i wonder how much a fuel addative could help clean that up? maybe once you get some new injectors in there run some howes meaner cleaner, for like... ummm 25-30 tanks lol

 

One great advantage to water inj, the inside is as clean as when it was new, the water cleans carbon out.