advise on a desiel injector puller

[jboy012000]

Hi All,

Hope everyone is doing ok.

I have a 2008 M59 Berlingo van, with a 1.6HDI engine.

I need an injector puller as I need to replace the seals on one of the injectors, can anyone advise a good one, there are a few options and I don't want to buy one that doesn't have the correct adaptors for the injectors in the 1.6.

Cheers

John

[pluggit1]

Did mine couple of years ago. Three came out from an hot engine with a bit of twisting, tapping and coaxing. Fourth one was a pig and even refused the slide hammer. Dont go paying silly money, an 8 piece slide hammer from a certain auction site for £25..ish will do the job and covers all the main injector brands. Be careful with the injector head though. Set out to get it out on the first half-dozen strikes from a pre-soaked block or you may be at risk of snapping it in the block and then you are well stuffed. Have a long reach magnetic pick-up for that "oh b###ks" situation and a vac with an half inch rubber pipe taped to the end of the floor tool to suck up all the crud from around the injector seat and down the hole. And if in any doubts dont be too proud to let a garage do it. Its a job that CAN go horribly wrong.

[jboy012000]

Did mine couple of years ago. Three came out from an hot engine with a bit of twisting, tapping and coaxing. Fourth one was a pig and even refused the slide hammer. Dont go paying silly money, an 8 piece slide hammer from a certain auction site for £25..ish will do the job and covers all the main injector brands. Be careful with the injector head though. Set out to get it out on the first half-dozen strikes from a pre-soaked block or you may be at risk of snapping it in the block and then you are well stuffed. Have a long reach magnetic pick-up for that "oh b###ks" situation and a vac with an half inch rubber pipe taped to the end of the floor tool to suck up all the crud from around the injector seat and down the hole. And if in any doubts dont be too proud to let a garage do it. Its a job that CAN go horribly wrong.

what a weekend it's been.

My issue was black oil / tar stuff all over the injectors area, everything led to a knackered injector seal, so Saturday, me and my dad set about cleaning the engine bay, it was filthy, this is the first diesel I have ever owned, so we had some learning to do, what did I learn about this engine, its been pretty much abused, poorly maintained and bodged wherever possible, however we went through a mock procedure of what we needed to do to change the injector, so that was Saturday.

When I got home I ordered a set of injector seals, got up this morning went back to my dads house, and we cracked on, we stripped out everything we had to, we even took the crankshaft cover off and to our absolute amazement the face of the rocker was chipped, pitted and really badly damaged, it looks like at some point someone has tried changing an injector and used a crowbar prised against the rocker to get the injector out, honestly I was gutted, but as I ordered the seals we figured what the hell, whip out the injector anyway and to be fair the old seals were shagged and ready for changing, to get the injector out we used a ring spanner to turn the injector and then used a large screw driver to push the injector up, we prised against a small piece of wood, so we didn't damage anything on the engine. It didn't take much to get the injector out and my dad had the proper tool to remove the seal that gets stuck in the bottom.

Whilst we were waiting for the seals to be delivered we concentrated on the damaged rocker. My dad has some two part epoxy e metal, we mixed some up and filled in the damaged area, once it was hard enough we filed it as flat as we could, then we used some blue liquid gasket as well as the rocker cover seal when we put everything back together.

Got to say, I couldn't believe it when I drove it round got the engine up to temperature and it is bone dry. Drove it home and yip, dry.

It's been a long weekend, wet at times, even worked through the thunder and lightning but we learned so much about the engine, and to be fair we've had a great time, we haven't got together and worked on an engine since the pandemic, so this weekend has been brilliant.

I still might get the proper injector removal tool, no doubt I will need to change another injector in the future and would hate to be stuck.

Happy days

[pluggit1]

Sounds like you had a fun but successful weekend. 

These PSA diesels - especially the 1.6hdi can do 200k without major work but they have to be given lots of tlc. Ive just done a 1500 mile round trip to the Scottish Highlands and it never missed a beat, and its done 163k now. With this engine its oil/filter and no more than 6k between changes. ALWAYS use 5w-30 and go for full-synth - £17 from Asda and a Bosch filter at £10. Price up a rebuilt turbo and possible engine strip-down because the vanes have blown 8 ways from Christmas and that £27 every 6 months looks bloody cheap.

Start treating it to some diesel additive every 3rd fill up as well. People have their own opinions on this but its kept my engine clean as new. I cant find any crud anywhere - EGR, just like new when I last pulled it off. And, speaking of EGR, bang a blanking plate in. I did mine some months ago - it keeps combustion out of the oil and engine and puts it out the exhaust where it belongs. It pulled like a freight train before but its got that bit more response now and the mpg has improved - quite a bit if my figures are right. I know some people will scream blue murder about global warming and their lungs but they aren,t paying for my new engine when it explodes because its choked itself to death.

I would pull the other three injectors and sort them too. Those copper seals can be a pig to get out but thats the seal, not the plasitic ones at the top. Careful when torqueing up that securing nut, it too can snap. I do mine hand tight and then same again after a warm engine.

If you can get to it, drop the sump pan on an oil change and check/clean/replace the oil strainer and pull the pipe off the turbo and get your thumb/finger in and check for excess end-play on the shaft. There should be no more than the slightest movement. Turbo oil-feed pipe has a mini filter in it. If that blocks its goodbye turbo so maybe another little job for a quiet weekend. PSA actually advised to take this out if possible as it was doing more harm than good in older engines but again, regular oil/filter changes and a clean burning engine will avoid these concerns.

All this kind of info is readily available on here from chaps(and gals of course..) who have lots of knowledge to happily share. They have helped me out no end. Ive just tried to share my experiences with this particular engine with you in brief as its new to you. I would never have anything but a diesel to be honest but they are now becoming socially unacceptable and wont be around for much longer.

And.. a big Ps : Short and stop/start runs kill these engines very quickly. Give it a run down a fast road at above 2000 revs for 10-15 miles once a week at least. It gives the DPF a chance to do a full re-gen and dont worry if you smell a mild burning now and then, its the DPF doing its regen cycle. 

Hope this all helps and gets you looking around the forum.

Chris

[jboy012000]

Sounds like you had a fun but successful weekend. 

These PSA diesels - especially the 1.6hdi can do 200k without major work but they have to be given lots of tlc. Ive just done a 1500 mile round trip to the Scottish Highlands and it never missed a beat, and its done 163k now. With this engine its oil/filter and no more than 6k between changes. ALWAYS use 5w-30 and go for full-synth - £17 from Asda and a Bosch filter at £10. Price up a rebuilt turbo and possible engine strip-down because the vanes have blown 8 ways from Christmas and that £27 every 6 months looks bloody cheap.

Start treating it to some diesel additive every 3rd fill up as well. People have their own opinions on this but its kept my engine clean as new. I cant find any crud anywhere - EGR, just like new when I last pulled it off. And, speaking of EGR, bang a blanking plate in. I did mine some months ago - it keeps combustion out of the oil and engine and puts it out the exhaust where it belongs. It pulled like a freight train before but its got that bit more response now and the mpg has improved - quite a bit if my figures are right. I know some people will scream blue murder about global warming and their lungs but they aren,t paying for my new engine when it explodes because its choked itself to death.

I would pull the other three injectors and sort them too. Those copper seals can be a pig to get out but thats the seal, not the plasitic ones at the top. Careful when torqueing up that securing nut, it too can snap. I do mine hand tight and then same again after a warm engine.

If you can get to it, drop the sump pan on an oil change and check/clean/replace the oil strainer and pull the pipe off the turbo and get your thumb/finger in and check for excess end-play on the shaft. There should be no more than the slightest movement. Turbo oil-feed pipe has a mini filter in it. If that blocks its goodbye turbo so maybe another little job for a quiet weekend. PSA actually advised to take this out if possible as it was doing more harm than good in older engines but again, regular oil/filter changes and a clean burning engine will avoid these concerns.

All this kind of info is readily available on here from chaps(and gals of course..) who have lots of knowledge to happily share. They have helped me out no end. Ive just tried to share my experiences with this particular engine with you in brief as its new to you. I would never have anything but a diesel to be honest but they are now becoming socially unacceptable and wont be around for much longer.

And.. a big Ps : Short and stop/start runs kill these engines very quickly. Give it a run down a fast road at above 2000 revs for 10-15 miles once a week at least. It gives the DPF a chance to do a full re-gen and dont worry if you smell a mild burning now and then, its the DPF doing its regen cycle. 

Hope this all helps and gets you looking around the forum.

Chris

Hi Chris,

i'll be honest, I love the van, I originally got it with plans to upgrade it next year, but like you say, it pulls along nicely and never misses a beat. I am with you on the EGR valve, it's on my list of jobs, although the guy I bought the van off promised me he had serviced it, looking at the air filter I would say he is lying lol, so first chance I get I will do a full service.

I got the van and use it pretty much only for long runs, I am a scuba diver and wanted something to carry all my kit and even sleep in if its a weekend dive trip, I might use it to go to work in for a few days to keep the battery alive, but it certainly gets a good few hundred miles round trip every couple of weekends, we are off to Wales this Friday afternoon for the weekend, really looking forward to that.

Thanks for the tips on the engine, I will do them the weekend I do the service, tonight I am whipping the builbs out of the back of the clock, get them replaced.

The engine has done 144,something thousand miles so I am going to keep it as long as it will run, it's a great van and the engine is actually really easy to work on, compared to some vehicles i've owned in the past.

Happy days

John