HOW TO: Remove a CDI injector with "black death"

[V12]

Good how to Olly.

Just to add we have had a few where no slide hammer in the world will remove the injector, in this case the special klann removal tool is best but it does render the injector useless and you will need a new one.

I had one on my old E 320cdi that wouldn't budge with the slide hammer. We left it overnight with a coca cola bath and it came out nice and easy the next morning.

 

[V12]

Olly - many thanks, as ever, for posting an informative writeup.
Speaking as a non-diesel-owner (nothing against them, but one's never fallen in my lap, so to speak)... why are they such a sod on these engines, and what the HELL is all that carbon mess?!

The injectors fire at such a high pressure, bolts can stretch and copper washers can wear. You can usually hear it when they start going as a "ticking" accompanied with diesel fumes. As with most car maintenance, the earlier it's treated the better.

 

[BlackC55]

Good how to Olly.

Just to add we have had a few where no slide hammer in the world will remove the injector, in this case the special klann removal tool is best but it does render the injector useless and you will need a new one.

Is that the fork type?

I have never failed to remove one with the slide hammer. My one attaches to the top of the injector so the force is linear.

 

[BlackC55]

Olly - many thanks, as ever, for posting an informative writeup.
Speaking as a non-diesel-owner (nothing against them, but one's never fallen in my lap, so to speak)... why are they such a sod on these engines, and what the HELL is all that carbon mess?!

The carbon is solidified combustion gas.

I find that most of the time the reason for leaking is that the injectors have been replaced at some point but not very well.

 

[jaymanek]

Is that the fork type?

I have never failed to remove one with the slide hammer. My one attaches to the top of the injector so the force is linear.

No the Klann fork type is stage 1 for us.
The screw into top of injector with slide hammer is Stage 2
This is the Stage 3 tool www.supplier.az - Removal of Injektor Nozzles with Spindle Merc. CDI KLANN Vugar Yunis - Azerbaijan. - YouTube

 

[E270 Owner]

F

Sometimes the force used to remove the injector can damage it. If that is the case replace it.

Olly

Removing the tops of injectors and slide hammering them can/will render them in need of re-calibration or replacement,
if you have to remove the tops of injectors and use a withdrawing tool (Klann stage 2/3) or a home brew slide hammer,
have them checked before refitting, it will save time diagnosing a non starting engine and prevent any engine damage due to over/under fueling injectors.

Nice pics btw








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[Terry_]

Good how to. I have had them siezed in so bad the head had to be scrapped! Personally I prefer timeserts to helicoils but its horses for courses so I'm told

 

[BlackC55]

Good how to. I have had them siezed in so bad the head had to be scrapped! Personally I prefer timeserts to helicoils but its horses for courses so I'm told

So far I've never failed to get one out!

 

[davidjpowell]

Many thanks. That's helped me decide that my car is off to a garage. Wish you were more local...

 

[Fatblokes]

Crack

Hi, I have removed my injector by using an ill fitting tool I got from eBay, whist doing this I have put a small crack in the casing, is this under pressure? Or would I get away with using evo stick epoxy metal to repair? Thanks

 

[spraydizzy]

Noooooooooooooooooooo!!!!!!!!!! Stop !!!!!!! don't use that adjustable spanner !!!!!!!
There's a special tool for that application you can rent it on eBay search eBay for " CDI Injector Puller"
Its a slide hammer with the correct fitting which screws onto your injectors then
Tap Tap Tap and their out in Three seconds ! ok
Hope this helps )

 

[bob6600]

Hi, I have removed my injector by using an ill fitting tool I got from eBay, whist doing this I have put a small crack in the casing, is this under pressure? Or would I get away with using evo stick epoxy metal to repair? Thanks

In the casing of the injector? If so, you will need a new injector

 

[Fatblokes]

Reply,

No the injector Is fine I have put a little crack in the rocker cover, just wondered if the cover was under a lot of pressure if not I was thinking of using metal epoxy resign to seal. Thanks