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Changing injectors: with the right tool...

Injectors in modern common rail diesel engines tend to wear out with age, refer to report “Injectors for common rail diesel”.

In the case of the fairly common Volvo D5244Tx with swirl flaps, as used in the V70 P26, S60, S80 or XC90, the injectors have to be removed before the swirl flap can be replaced. If the injectors are not removed, it is not possible to dismantle the intake manifold, which is also the valve cover.

When removing injectors and injection lines, meticulous attention should be paid to cleanliness, and connections should always be covered to keep dust out.

Even when an injector has been removed, its seat should be covered with a suitable plug if it is not currently being worked on. If something falls into the seat, it may be necessary to disassemble the cylinder head!

Always open the injection lines very slowly and carefully to allow the pressure to escape slowly. Wear protective goggles and gloves when doing this, as the pressure in the distributor pipe can be very high!

Depending on the damage, it can sometimes be quite easy to diagnose the defects in the injectors. A compression pressure that pushes past the injector seat can usually be heard; a regular ticking or hissing sound from the seat draws attention to it. It can usually also be seen through clear soot marks. With a bit of luck, you will only have to pull the injector once and carefully clean the seat and injector with the appropriate tools (1041785, 1099448, 1099451)

1041785	1099448	1099451	1078256

Then the injector is reassembled with new seals, brackets and screws. It is essential to use new assembly parts.

If the assembly parts are not new, the injector can dance in the worn-out holding bracket due to compression pressure and injection pressure. This either bends the retaining bracket or tears out the threads in the cylinder head. Such damage can usually be repaired with thread inserts (1078256), but it doesn't have to come to that.

It becomes more difficult, however, when an injector no longer opens or closes properly, resulting in a poor spray pattern. The first, fairly reliable test would be to measure the leakage oil; there is nothing more that can be checked with relatively simple means. To do this, the leakage oil quantity is measured in measuring glasses. If the quantity of an injector deviates significantly upwards, the injector of this cylinder is defective and must be replaced.

1093241	1080399	1100084	1100086

To pull the injectors, the drain line, pressure line and connector must be removed. An open-end or crow's foot wrench (e.g. 1093241, 1080399, 1100084, 1100086) is helpful for the lines. The hoses should be replaced according to the vehicle manufacturer, because they could leak at the flange if used repeatedly. Then the retaining bracket must be unscrewed. The seats should be soaked in injector solvent (1060549) at an early stage, if this can be left long enough, then they can usually be easily removed.

1065523	1064396	1078254	1073402

If they are to be reused, a slide hammer (1065523, 1074165) with the puller 1064396 is the right tool for D5 engines. The puller engages under a collar on the injector and allows it to be pulled without damage. If more force is required to pull it out, there are adapters (1078254, 1073402) that can be screwed onto the injector after removing the electrical part. Then a larger slide hammer can be used, but as a rule the injector will no longer work and will have to be replaced.

1074165	1073403	1080522	1060549

If new injectors are to be installed after cleaning the seats, a positioning device (1080522) is required for the D5 to align them correctly. This ensures that the nozzles point in the right direction with the connections and, above all, that the new pressure lines can be installed properly.

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