how to remove stuck injector on a perkins?

skata · Jun 10, 2019

i have a 96 perkins 1004 engine with lucas injectors.
first one came out real easy, the next took some twisting back and forth and lots of penetrating oil. the third was really stuck. managed to twist it loose slightly and kept working back and forth probably a couple hundred times until it finally came out. now the 4th injector is stuck pretty good. it seems that end of the motor got more rain water due to the hood design. so more rust in the injector bore.
i used a breaker bar and socket and am able to twist the upper portion (counter clockwise) of the injector loose. but the bottom wont turn when turning clockwise. i have a hammer slide coming tomorrow. though it only has a 1lb hammer on it. i couldnt find anything else online. any pointers to get it out?

Ronsii · Jun 10, 2019

Haven't ran into this myself but maybe something to get in there and eat the rust???acid??? just thinking out loud

thepumpguysc · Jun 10, 2019

U seem to be missing a part on that 1 that's apart.?? Spacer plate w/ the pins in it..
How did u get it out if it was stuck??

funwithfuel · Jun 10, 2019

B'laster and patience. The slide hammer should help. Vibrations will help loosen the grip

TVA · Jun 10, 2019

Air hammer

DMiller · Jun 10, 2019

Had luck with prying the cup seal out and flooding the area around the barrel with acetone and then PB before.

skata · Jun 10, 2019

thepumpguysc said:
U seem to be missing a part on that 1 that's apart.?? Spacer plate w/ the pins in it..
How did u get it out if it was stuck??

that partial injector is another one i took apart. the stuck injector is fully intact in the block. though i could unthread the upper portion of the injector off, but i'm not sure what that will acomplish, or if its a good idea.

skata · Jun 10, 2019

DMiller said:
Had luck with prying the cup seal out and flooding the area around the barrel with acetone and then PB before.

i did just that yesterday. gonna wait for this hammer slider to come that i ordered, and hopefully knock it loose.

DIYDAVE · Jun 10, 2019

While you're waiting, it wouldn't hurt to soak the area with Kroil, or 50/50 acetone/ATF mix, or your favorite panther ****(penetrating oil)...

buckfever · Jun 10, 2019

I had this happen on a komatsu dozer once. Found a lug nut at Napa that threaded onto the injector and made a puller with it. Took a lot of force to get it out but it eventually pulled out.

skata · Jun 11, 2019

so the slide hammer i ordered didnt get here until 7pm. the weight is only like 1.5 lbs. i hit the thing maybe 50 times. nada. soaked with penetrating oil, and dumped acetone on there. when i was done hiiting, i put the socket on and was able to turn the injector clockwise some more from when i tightened it yesterday. so perhaps its budged? or the injector threads are strippping?? hope not. lol
was getting dark, and i'll tackle this tomorrow. i need to come up with a way to apply upward pressure on the injector, while using the slide hammer. and i'll try twisiting it some more. wish me luck!

thepumpguysc · Jun 11, 2019

Get someone to turn it while u use the s. hammer..

skata · Jun 11, 2019

Ok. I'm f@cked. I ended up stripping the threads of the injector and the upper part came out and lower piece is still in the head. At least one good thing, the nozzle comes out so perhaps I can drill this stuck piece out. Seems to be a 21.5mm bore. I see I can get 21.5mm cutters online. Any other ideas?

skata · Jun 11, 2019

This is what I need to drill out.
I don't think it matters if I scuff up the bore doing so as the seal is on the bottom.

Labparamour · Jun 11, 2019

Can you make a “j” hook for the end of your slide hammer and go through and catch the bottom of the injector?
Maybe heat and solvent on edge of injector at top of head?

funwithfuel · Jun 11, 2019

Well, now you can get in there with a blunt chisel bit on your air hammer and break that rust up. I'd try and stay away from what's left of the threads in Hope's you could screw another body into it for pulling.
Good luck

funwithfuel · Jun 11, 2019

Maybe consider this in the future.

DMiller · Jun 11, 2019

I agree on the J Hook or fashion a adaptor to go into the nozzle bottom hole as a Blind Hole puller and slide hammer that piece out, the second you set a drill to that you are asking to buy a new head as that is a THIN region of that head.

Cmark · Jun 11, 2019

I'm afraid it's time to cut your losses, pull the head and take it to the machine shop.

thepumpguysc · Jun 11, 2019

Cmarks got the right idea.. & the way u should proceed from here on out..
SKATA> Your 1st sentence is right on the money..{post #13}
A cutter aint gonna do it..
Is that an injector tube, the inj. is in?? no wonder its stuck..

IF a slide hammer stripped the threads of the injector.. do u guys REALLY THINK a J-hook is gonna help.?? U cant get UNDER the bottom of the injector.. its sealed w/ a copper gasket to the head..

how to remove stuck injector on a perkins?

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