Volvo D5 - Removing stuck/seized Diesel Injectors

Removing injectors on a Direct-Injection Diesel engine will always have the potential to ruin your plans - I anticipated this one well in advance, and had to resort to a slide-hammer extractor kit to remove one.
(Apologies for the inconsistent audio quality - I had a bit of hardware failure making the video!)

[@svenladegast2518]

There is a slide hammer which grips onto the lower edge of the body. I used this to extract 2 of the injectors that were stuck on my engine. The advantage is that the injectors did not get destroyed. Cleaning is easy with a rotating wire brush, even at the nozzle portion. They looked and work like new when I took them back in.

[@MuddyBiker]

Look forward to seeing the next step 😬

[@matthewwiddows6319]

for others watching, if you have a leaking injector thats showing that black tar around it and your thinking of sorting in the future as the car is running ok at the moment. keep regularly applying carb cleaner and then use an air duster on a compressor to blow down the injector hole. this will slowly release all the crud.

[@johnwilson6111]

I have an injector that has not yet moved after using three different slide hammers on it. Even broke the adaptor claw that slips either side of the injector body in the second slide hammer kit, so that went back to the store. I've also bought and tried a pneumatic vibrator tool which was defective so was sent back to the seller for refund. I have a bigger slide hammer kit now and so far it's not working. I've used different penetrating fluids without success. I may have to fabricate something to use with a hydraulic kit if the slide hammer is ineffective.

[@claywebb8199]

I’ve removed a stubborn injector before by warming the engine up then loosening the retaining bolt very slightly (if they are that design) and fired up the engine again. The combination pressure dislodged the stubborn injector.

[@rasmuzt9260]

do you know the thread size you used? And do you ruin the injector if you do this?

[@MrZakmuh]

Try removing the injector without removing the solenoid actuator ( the top connector housing). This messes up the calibration. You will have to recalibrate it through a diesel or injector specialist or replace the entire injector with a used working one. You don't have to code/programme the replacement injector but Bosh's part number should match number to number. Volvo's part number irrelevant.

[@cookstrap]

Hi Chris did you replace with new injector or second hand ? 1👍

[@barrybritcher]

Freeze spray