Injector stuck in head

[ROCK HARVEY]

After you screwed in your turned-down injector, did you try tapping it with a hammer to get it moving? It shouldn’t hurt anything since the only thing holding the tip in place is carbon (no threads).

What are you soaking it with? I wonder if a gun cleaning solution would be best since it will dissolve the carbon.

 

[ROCK HARVEY]

Here’s another semi-crazy idea. What if you put the rest of the injectors back in and fired it up? The compression might shoot the stuck injector tip right out of the hole.

 

[miked]

It is out.
It was pretty obvious this morning that I was not going to get anywhere using the same techniques and I had to come up with a different plan.

I measured the injector bore in the head
.800
I measured an injector barrel
.665

And decided I could make a type of hole saw that would remove the carbon between the bore in the head and the barrel of the injector.

I found a piece of 7/8 shafting in my steel pile.

I turned the od to about .790 with the length matched to the depth of the bore this gave me a shoulder as a depth indicator.

I used a 43/64th drill to a depth of 2 inches.

Put 4 pretty teeth on it and thought I would ream out the carbon quickly.
That did not happen

, I ended up with one little square tooth that I twisted back and forth with a vise grip, and the only way I could tell if it was working, was the puff of black when I blew out the hole when I adjusted the tool in the vise grip.
Took about 2 hours to rub my way down to the bottom, but it did work.
A piece of high carbon steel that I could harden may have work better but I hope I never have the need to find out again.

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[miked]

Of course the copper washer did not come out with the barrel. Maybe there is not one. would have explained all the carbon. I haven't looked yet.
My thinking I had bell mouthed the thread was that I had in fact cracked the barrel section stuck in the head.

I plan to put air pressure into each cylinder when I clean out the bores but that will have to wait until I reinstall my injection pump.

 

[miked]

I tried different pentrating oils but did not think of gun solvent

 

[BeastMaster]

How did you get your custom hole saw in the injector hole with the stuck injector blocking access? Did you end up shearing the stuck injector off at the tip and end up pushing it back out toward the piston? I take it you had to remove the head to do this, avoiding contaminating the cylinder.

I have been following your posts quite avidly - I have learned so many *useful* things here thanks to the people here like you that post their situation and all the others who offering what they have. This is the kind of knowledge that will save us all should society as we know it collapse and we suddenly have no one to keep our machines running. It's happened before. It's knowledge like this that will have an impact on whether we survive a societal collapse or not. The Devil is in the Details. For the want of a nail, the shoe was lost...you know how that went. I really hate to lose an engine over a bit of carbon. That engine is the culmination of a helluva lotta contributions from a huge number of people who designed and built it, while so many of us take these gifts for granted.

 

[miked]

Hello BeastMaster
In post 13 I described how I was able to unscrew the top part of the injector out of the head. But it had also unscrewed itself from the bottom barrel section. Leaving it stuck in the carbon.

To use this tool, the top section of the injector (with the top threads turned off) was not installed back onto the lower section. I planned to screw it back on after removing the carbon.

What actually happened was the stuck section ended up coming out with the tool because the tooth did not have a set like a sawtooth would have, and the carbon was a tight fit to the OD and ID. You can see how it was polishing the OD of the tool.
This friction fit lifted the bottom section out when I lifted the tool out for the last time.

The stuck section was blocking access to the hole to the combustion chamber so no debris could get into it while I removed the carbon

 

[ROCK HARVEY]

Congrats and well done!

I would not have thought of making a hole saw to cut out the carbon. I’m really glad it worked out, thanks for keeping us updated.

 

[miked]

Thanks, I did a little searching and did not find any reference to this having been done before.
So I gave what I hope was a good enough description so that others could also use this if their situation warranted it.

The person who put these injectors in did not clean the bores. Looking at the rest of the injectors that did not leak. The copper washers on many had material inbeded in the copper

 

[ihc1470]

Different style injector is used on the DT300-400 series engines in that they clamp down rather than screw in. They will also stick into the heads at times often because the umbrella seal at the top leaks. On those I use an old injector line that I cut off at about 8 inches long then I take a piece of 2 inch round shaft about 2 inches long with a hole drilled through that is just large enough to allow the injector line to pass through. Weld something on the top of the line and it makes a nice little slide hammer to help pop the injectors out of the head. You could of used the same idea where you had turned the threads off the upper body. Not sure you would have had the room though.

Glad you got it out and I like the idea you came up with.