How do I get my PD Injectors out?

Discussion in 'VW Mk4 Jetta, Golf, New Beetle, Passat TDI forum' started by robinofbristol, Jun 3, 2011.

  1. robinofbristol

    robinofbristol New Member

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    Old school hotrod guy at heart, this one is the fa
    Finally gave up on the engine and have bought a 40,000 mile replacement which arrived today. Changing over all the missing bits I decided to swop the rocker covers and couldn't believe my eyes...the swines have taken the injectors out and stuck the cover back on. So I need to swop out my original injectors to the new engine...I got the bolts and spacers out and I can turn them a little left and right...but how on earth am i supposed to pull them out? I can't see anything else holding them in place so I guess it is just the O rings being tight. Should I wrap some wire round the springs and tie them to the engine hoist and try pulling them out of the engine? I can't get a lever in there and I can't think of any suitable tool...even if I has a slide hammer I have no way to attach it.

    Any suggestions.... anything considered.
     
  2. chittychittybangbang

    chittychittybangbang Administrator

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  3. robinofbristol

    robinofbristol New Member

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    Old school hotrod guy at heart, this one is the fa
    Very helpful.... but I need them out tomorrow, I can't wait 3-5 days for a T10055 special pulling tool. It looks fairly basic, I might try making one while my Son tries all the VW specialists in town to see if anyone has one off the shelf. Oh well at least I know there is a place I can use to lever them out... I am on the right track.
     
  4. robinofbristol

    robinofbristol New Member

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    DIY Injector extraction tool

    As I couldn't wait....I decided to shave one side off a long (motorbike engine) bolt, I guess the shaft was about 8mm and 220mm long and the head about a 15 or 16mm with a built-in washer...the nut for the other end was the same design. I filed down one flat right to the shaft of the bolt and filed of about half of the top surface too. the remaining lip hooked nicely into the side of the Injectors (where the retaining spacers came out) and all I needed was something with some weight to use as a slide hammer. One of my medium sized axle stands temporarily gave up it's middle and the pin holes just happened to be a nice loose fit over the bolt...nut in place and a couple of upward taps and... bob's your uncle.

    Now how much did they want for that T10055 special tool that would take 4-5 days to deliver?
     
  5. chittychittybangbang

    chittychittybangbang Administrator

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  6. jetta27

    jetta27 New Member

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    2004 Jetta
    Injectors will not move

    sorry to jump in but I am having a similar problem.

    I am trying to get my injectors out but unlike your injectors mine will not move. I can not get them to even adjust left to right. I made a tool as you did and nothing will budge! I have to get them out because they are leaking diesel into my oil. Is there anything I can do to try to get these things out?
     
  7. gotdisl?

    gotdisl? New Member

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    Jun 25, 2012
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    Car:
    2004 Jetta TDI PD
    removing injectors

    Anybody in NC, near charlotte has the T10055 tool for sale or for me to rent/borrow? Injector removal tool!!thanks
     
  8. CraigT

    CraigT New Member

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    Good day I stripped the head down and put in the oven at 150 degrees F. I found that the injectors came out alot easier and they woouldn't budge before I warmed the head up.

    Cheers and good luck
     
    dweisel likes this.
  9. chudzikb

    chudzikb Member

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    Nice tip, I can see my wife killing me for doing that one, would not be good for me!
     
  10. sgtgoober

    sgtgoober New Member

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    Little Rock, AR
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    .205 injector nozzles
    The injectors in my ole TDI were pretty stubborn about coming out until I sprayed a little PB blaster then used the metalnerd slide hammer. I've heard of some ppl using an old fuel line as well.
     
  11. lukeykookey

    lukeykookey New Member

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    HI everyone. Absolutely great site! (Although cant see a link to donate??)

    Anyway. I have the same issue and need to remove an injector on my VW AZV 2.0tdi engine, after C2 misfire issues (changed loom already at £100 - no difference)

    This engine is a DOHC. Are there any tutorials for this - I imagine the procedure is very similar but don't want to do something wrong.

    Many thanks in advance and keep up the good work - also how do I donate!
     
    mk5tdi likes this.
  12. lukeykookey

    lukeykookey New Member

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  13. Ted Tolentino

    Ted Tolentino New Member

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    robinofbristol, if you still have your home made tool for pulling the PD injectors, could you share a picture or two of what the tool looks like. I, too, have injectors I need to remove from my 2004 PD engine. A million thanks.
     
  14. morganc

    morganc New Member

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    2005 allroad tdi
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    reno, nv
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    tdi
    I used robinofbristol's technique and it works well. I had a slide hammer and got a bolt that fit it. I shaved down one side and the top to make it thinner. Slipped it in...tap tap tap and it out. I'll upload pics. Cost was $2 for a metric single bolt at home depot in M 14X80.
     

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