how to remove stuck injector on a perkins?

skata · Jun 11, 2019

I wasn't getting anywhere with the slide hammer so i used a socket and breaker bar and turned the injector clockwise in hopes of breaking it loose. Instead I stripped the injector body.
I'm not sure a j hook will work. I'm guessing the nozzle is the same diameter as the hole in the head. So there wouldn't be anywhere to grab.
I ordered some carbide hole cutters and bit . I'm going to try drilling it out before I will take the head out.

thepumpguysc · Jun 11, 2019

On the brite side.. you'll only have to take the old head off once..
.. just to get it out of the way for the new one.. lol.!!!
Good luck. {seriously}
Do u have access to an oxy/acet. torch??
Take another injector apart & use the body or see if it will screw down in the nozzle nut..
Fire up the torch & put it in the inj. hole & let'r get HOT.. real hot.. then screw the "new body" onto the nut & use a slide hammer to pop it up or use the air hammer method..
IF the body screws down into the stuck nut, I think it'll work.. IF u get it hot..

Cmark · Jun 11, 2019

If you're determined to proceed, the first trick you should try is cutting a thread in the injector body. It doesn't matter what pitch or thread form it is as long as you can screw in a long bolt and fabricobble a big slide hammer together. Use the best quality tap you can find, solid carbide preferably but at least HSS.
Whatever you do you will need to be really careful about getting swarf into the cylinder. Shove something into the hole like a foam ear plug.

fast_st · Jun 11, 2019

Take a fine tip oxy acetelyne torch and heat a few spots along that injector body red hot, the cup can't expand in the bore so the red hot will displace the metal, when it cools it'll shrink by a few thou easily. This works on anything that's in a tight bore, even a frozen bolt, drill a hole clean through it, blast it with a welding torch tip, when it cools you'd find the drill won't fit down the hole as the bore shrunk a bit.

DIYDAVE · Jun 11, 2019

Might be a good place to try the bolt buster, If you have enough left sticking out, to heat, But $400 bucks may be a lil pricey, for an experiment...

Otherwise, to save time and the head, either take the head to a shop, or take it off, turn it over, and get out the BFH, a suitable punch and hope for the best...

thepumpguysc · Jun 12, 2019

I'm at a lose as to what to "try" next.. because the only part that would be accessible from the underside would be the tip/nozzle.. but the only thing holding IT IN was the body.. & now ITS stripped out..
So u cant flip the head & pound on the tip.. IF I'm not mistaken, they sit in a brass sleeve..injector tube??
BUT IDK if they have to be reamed after they're put in..?? Because my next thought would have been, run threads in the tube & pull IT OUT along w/ the rest of the injector{noz. nut} BUT if it has to be reamed after install, that's prob. out of the question. {buncha new tools}
U would have to get an engine manual to tell or if u know what an inj. tube looks like, u can tell.. its just a thought..
Sorry bud, I think your up Sh*ts Creek w/o a paddle..??
I sure hope u have some luck w/ it..

fast_st · Jun 12, 2019

Have some hope, a little careful heating and shrinking and that should loosen up a bit!

thepumpguysc · Jun 12, 2019

I think "hope" & "luck" is ALL WE HAVE right now..

fast_st · Jun 12, 2019

I was game on warm up the engine, loosen injector and start engine, wait for the POP! then go find the injector.

thepumpguysc · Jun 12, 2019

THAT DOES work on some engines..
Cant do it now.. theres no "body" to hold the compression in..{stripped threads}

skata · Jun 12, 2019

The threads are part of the lower injector body half. That is the part I'm going to attempt to drill out. Rust is the only thing holding it in place.
The hole in the head is straight and smooth. The injector just drops right in. And there is a clamp and 2 bolts that hold the injector down.

mikebramel · Jun 12, 2019

Don't drill anything, cut threads with a new hss tap. Get a bolt the same thread and use a full sized slide hammer

fast_st · Jun 12, 2019

Cutting threads might work, depends on how thick the metal is, I imagine that rust has quite an expanded layer there. Guessing a welding torch isn't available for spot heating. if you could plug the hole into the engine, maybe a tuft of fiberglass, put a regular nut in there and mig weld it in place, you'd end up with the welding shrinkage and some stout threads to pull on. I love my gas axe, its so versatile

skata · Jun 13, 2019

My plan is to drop the nozzle back in the hole to prevent debris going into engine. And use a cutter like in the picture. I'll just remove the center bit. Just waiting for it to arrive. And no I dont have a torch.

hosspuller · Jun 13, 2019

I 'd endorse the heating that fast_st suggested. Torch or welder... Heating a constrained part technique straightened a bent fork that available brute force couldn't

Without the center drill on the cutter, there's nothing to center the cutting. You risk the head as pumpguy says.

fast_st · Jun 13, 2019

opportunity to buy a hot wrench!! Everybody likes new toolz!!!

funwithfuel · Jun 13, 2019

Even a mapp torch might help at this point. You can score one at the local ace for 40 or so. We are just trying to keep you from irreversible damage to the cylinder head. Whatever path you choose, good luck. You have your work cut out for you.

doublewide · Jun 13, 2019

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

Follow this man's advise.

Vetech63 · Jun 13, 2019

I have snapped off a few injectors in my time. I drilled them through the center just far enough to cut a few threads in it and used a bigger slide hammer. I haven't had one defeat me yet.

thepumpguysc · Jun 13, 2019

THAT TOOL looks like it'll get the job done.. Good luck.

how to remove stuck injector on a perkins?

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