Injector Removal – Case Studies

The case studies in this section are a selected sample of a large number of vehicles brought to Sharp Autos for diagnosis and subsequent injector removal.

Vehicle – Vauxhall Vivaro 2010

  • Fault Overview

Customer brought vehicle to us after unsuccessful and poor attempt at removing faulty injectors by a mobile service. Mobile service applied 20 tonnes to injector without any movement causing damage to the rocker cover and had removed the central threaded section of the injector. However, a non refundable full payment had already been taken in this instance.

  • Diagnosis

These later models are fitted with late solenoid 0445110338 which are beyond the equipment and skill capabilities of the majority of injector removal services.
Sharp Autos have found that due to the strength of these injectors and the level of corrosion they suffer, a maximum of 15 tonnes are used to remove these. If this doesn’t extract the injector, a more sophisticated procedure is required.

  • Removal

Faulty injectors removed using our specialist and custom built equipment. Injectors also supplied with no surcharge with payment only made on completion with damage on the rocker cover fixed by Sharp Autos.


Vehicle – Vauxhall Vivaro 2007 2.0 cdti

  • Fault Overview

Recovered to us from a main dealer with injector No.4 broken off at the threaded top section.

  • Diagnosis

This is caused by the OE tooling (very similar to ebay injector tooling) only pulling on the top part of the injector.

  • Removal

Injector very simply removed using our specialist equipment.


Vehicle – Renault Trafic 2008

  • Fault Overview

Faulty injector

  • Diagnosis

Excessive fuel correction on No.2 cylinder, caused by ecu attemping to increase fueling to a faulty injector.

  • Removal

With our extraction equipment applied we increased pressure on the injector to 8 tons. This injector was not moving and an increase of pressure to 9 to 10 tons will always cause these piezo units to shear. After leaving the 8 ton pressure applied and some forceful manipulation over the period of 3 hours, the injector moved a couple a millimetres with a familiar “pop”. Once this initial break was completed, the rest of the extraction was once again straight forward.


Vehicle – Vauxhall Vivaro 2007

  • Fault Overview

Injector No.3 sheared off half way down under collar.

  • Diagnosis

The vehicle was brought to Sharp Autos after the faulty injector had been sheared by a mobile injector removal service applying too much force too quickly to these problematic injectors.

  • Removal

Our team of fabricators developed a new tool to extract the sheared injector which was later successfully removed.


Vehicle – Nissan Primastar

  • Fault Overview

Faulty Injector

  • Diagnosis

The vehicle was brought to Sharp Autos after first being taken to a Norwich garage who proceeded to weld a nut to the faulty injector to assist in a crude attempt at removal. This approach led to the injector breaking under force and subsequently flush with the cylinder head. With a expected repair of a new cylinderhead, the customer arranged transport of the vehicle to Sharp Autos, who after assessment took a different approach to a standard injector pull.

  • Removal

Using our specialist equipment, our experienced operators removed this troublesome injector in 4 hours.


Vehicle – Renault Trafic

  • Fault Overview

Vehicle suffering from hesitation under full load

  • Diagnosis

Sharp Autos’ specialist diagnostic equipment discovered the following fault : Injector 3 – Short Circuit.

  • Removal

Our team removed the necessary engine covers and using our latest technology, found an easy to remove injector (3 Tons extraction). These extractions also include cleaning the injector bore, resurfacing the injector seat and coding the new injector to the ECU.


Vehicle – Vauxhall Vivaro 1.9

  • Fault Overview

Cylinder head sent to us after suffering a snapped cam belt

  • Diagnosis

Injectors require removal along with cylinder head overhaul.

  • Removal

Sharp Autos removed all four injectors, had these units reconditioned, and had the cylinder head overhauled, with bent valves replaced, for a fraction of the cost of 4 new injectors and a recon cylinderhead


Vehicle – Peugeot 807

  • Fault Overview

Excessive leak back on number 4 cylinder

  • Diagnosis

Problem confirmed with a simple leak off test

  • Removal

After strip down and our injector puller applied we removed this injector, had it reconditioned and refitted within a day


Vehicle – Vauxhall Vivaro

  • Fault Overview

Vehicle taken brought to us after vauxhall dealership diagnosis which condemmed all four injectors. When the dealership had tried to remove them, number 1 injector broke off at the top. They subsequently abandoned the removal attempt and priced up the vehicle for a new engine as head bolts cannot be accessed with injectors in place.

  • Diagnosis

After arranging delivery to Sharp Autos, we diagnosed a fault only on no 3 injector. Sharp Autos only recommend removing faulty injectors rather than all 4 due to the unnecessary inherent cost involved.

  • Removal

After removing the damaged injector and the faulty no3 injector, cleaning the injector bore ,re-cutting the injector seat and coding in the new units,this vehicle was road tested and completed for a fraction of the original vauxhall estimate.

 


Vehicle – Mercedes Sprinter

  • Fault Overview

Vehicle suffering from smoke when idling.

  • Diagnosis

These vehicles are fitted with the 115 series injector which are common for ‘drippy nozzles’.  To compound matters, all four had been leaking gases on the sealing washer causing a large build up of carbon.

  • Removal

After removing the carbon, cutting the seats and fitting with new injectors and clamp bolts, all problems were resolved.

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