Removing a snapped injector bolt (Mercedes CDI)

[Mr_Bo11ox]

Nip up the 8mm bolt with a breaker bar

[Lankytim]

Good idea! I'll go and get a scaffold tube to go on the end tool

[jonathan_dyane]

Well worth £85 IMHO. Shit design.

[NorthernMonkey]

It'll need the seat cleaning with the proper reaming tool rather than a bit of emery paper on a stick. You can get a set for £15 from the bay that'll do for occasional use...the surface needs to be spotless so a new copper sealing washer stands a chance with the pressure involved.

[forddeliveryboy]

All done! The fella drilled the hole out an helicoiled it to take an 8mm bolt. Cleaned up the bottom of the injector hole with emery paper on a stick, stuck it together and fired it up!

 

No hissing or popping noises but a water test shows there's still a bit of blow by with lots of bubbles emanating from the base of the injector. BALLBAGZ.

 

HTF do I get this bastard to seal properly?

 

Ask the guy who did the helicoil, I bet he knows plenty of tricks, but njgleeds is probably 101.2% there. I knew of one chap who ditched the whole engine and replaced with a 603 turbo. He reckoned over the next 3 years/100k km he'd more than break even as well as have peace of mind and an engine which could be used in something else once his 21st century shitty MB rotted away.

[fordperv]

who was it local who did it tim? it might be useful to know if anyone asks me

[Asimo]

If it is blowing bubbles with you watching it, imagine how much it will leak at full boost / max torque!

[Lankytim]

who was it local who did it tim? it might be useful to know if anyone asks me

 

 

Alan, 0 77 88 79 3 ii4, Thread engineers.

[Station]

You need to use the cutting tool on the base and buy another seal to be on the safe side. The injector has to fire 2000 psi or whatever under TDC compression so any gaps and it will leak.

If it's helicoiled you may be able to tighten up a lil more.

[Station]

Failing that drill right through the block and hammer a bastard six inch nail into it.

[SiC]

RTV?

 

 

 

 

 

 

 

 

(I'm joking!)

[fordperv]

Alan, 0 77 88 79 3 ii4, Thread engineers.

brill I'll save that

[Lankytim]

He was absolutely brill and is used extensively by the trade. Very polite too!

[a60rod]

Had this issue, the trick is to have the aforementioned tool to cut the seat BUT you need to cut the seat of the actual injector too. Spin the cutter til the bit being cut is all fresh metal ie an even cut. Job done and trust me you can do the clamp up to a zillion ft lb and it will still fart if not cut proper.

[a60rod]

Oh and you may see burn marks on the seat of the injector. Yep the heat can burn the copper washer away partially. Quite a common thing by all accounts. PS the forums would make you kak yer pants if you believe half the crap the clueless merc owners go on about

[Lankytim]

Plenty of cheap injector cutters on amazon. Worth a punt?

 

 

Frigging can't paste the link now!

[Lankytim]

Just managed to fix this! The end of the injector had eroded away on one side, with a new nozzle thing and a thick Honda copper seal I'm now leak free, YES.

[Dave_Q]

VICTORY!