Advice On 638 Vito CDi Injector Removal

[Deleted member 37751]

Just taken a 2003 638 108 CDi Vito in with a starting problem that has turned out to be an injector that's knackered.

Trouble is, we are having a big problem getting the bloody thing out, are there any little tricks to 'persuade' it out? There's no black death on them.

Once the van is running, it's sweet.

Any help would be greatly appreciated, trying to get it out is becoming tedious...

 

[Deleted member 37751]

This Vito needs your help, it deserves to be saved; it's the only 638 I've come across without rust!

 

[nick mercedes]

it's the only 638 I've come across without rust!

Impossible.

 

[Deleted member 37751]

The paintwork is about 6" thick though...

 

[NOMONEYBUTAMERC]

Think you will find there are "injector pullers " available , possibly hire/borrow from local dealer/independent? Failing which , ask a local chav , they have a way of lifting just about anything

 

[Deleted member 37751]

The location of the injector makes it very hard to get the lifter in.

 

[Deleted member 37751]

For anyone vaguely interested, the injector is to be repaired in situ.

 

[Dieselman]

For anyone vaguely interested, the injector is to be repaired in situ.

It is actually interesting.

Thanks.

 

[st4]

Impossible.

Yep. I see rust inside the engine bay. Its always somewhere in a Mercedes

 

[Deleted member 37751]

It is actually interesting.

Thanks.

The seal had worn/broken and *somehow* he's replaced it without removing the injector.

If you are genuinely interested, I'll find out the procedure and post it on here?

 

[Dieselman]

I guess he stripped the upper section of the injector off the lower body, replaced the inner seals and refitted the upper section.
That's just the same as doing it on the bench, but more awkward as it's still on the engine.

 

[AdamG]

Was it suffering from excess leak off?

I think there is a teflon seal that wears causing this.

There is a video on youtube showing the strip down and repair of a bosch injector but he did it on the bench.

Common Rail Injector, strip & rebuild part 1. - YouTube

Doing that in the engine would be very tough.

Adam

 

[panason1c]

With the engine at full working temperature the injector will come out more willingly.

 

[gobike]

The slide hammer tool does not fit in the 108 cdi model. I ground a bit off first to get the tool U shaped part in, and used a small hammer at 90 degrees to knock the tool back and it levered the injector out. As it came up I put washers under the tool to maintain the leverage. I made sure the small bolt hole was clear of junk before reassembly, It would be a pig of a job if you had to fit a helli coil in there. Why do they not use a washer and spring washer on the bolt so it does not come loose? Any one tried a loc-tite compound on the injector seals by the way?