I'm in the process of replacing my nozzles with a set of Bosios which I procured from my TDI guru Peter at www.idparts.com $119.80 for 4. I've got everything out of the way, except I can't get 3 of the 4 heat shields out, usually it's the "rule of always one", but in this case it's 3. Any suggestions on how to get these things out? I've squirted a little PB Blaster around them and have a little hook tool, but so far no go. Is it dangerous to spray anything that might get into the hole, or will everything burn off when it's finally fired up?

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'82 240D automatic to manual (sold)
'84 300D (sold)
'12 MINI CooperS Coupe
'71 Triumph Stag
'76 MGB
'08 BMW 535XI wagon
'12 VW Golf TDI

That is an excellent price on the Nozzles.
How, was the shipping to your area?

About 3-4 weeks a go there was a thread on this and also about 2-3 weeks before that.

You all ready did the soaking; I am guessing the longer the better. Crank the Engine without the Injectors in to try to blow off any possible excess fluid.

Some have said to get a Punch and lightly tap around on top of the Heat Shield to loosen them. A Brass one would be better for that if you have one. After that you are back to trying to hook them or using a strong Magnet.

This is a Pic I copied from another Member of one of the Mercedes Forums. I don't know the details as to why the Prechambers are machined differently. But, make sure you are actually seeing a Heat Shield down there.

Attached Thumbnails

 

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84 300D, 82 Volvo 244Gl Diesel

It only took 2-3 days to receive my order, and shipping was free. Peter Noble owns idParts and is a very upstanding and respected guy in the VW TDi community. Here's the shipping policy:
IDFree Shipping Program - the IDParts Free Shipping program begins at $50 and is dependent on weight. The free shipping weight threshold goes up with order value. If your order qualifies "IDFree Shipping" a free shipping option will be avaible. Our free shipping program includes the one initial shipment only and does not cover second shipments due to address mistakes. Orders placed with free shipping cannot be changed or added to, rather, we must cancel your order and ask you to place a new order.

I will cont to soak the area and try your suggestions tomorrow. I will update this post as I proceed with the nozzle replacement. I look forward to getting this job done. I'm sure I'll have other questions as I go, but I hope not.

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'82 240D automatic to manual (sold)
'84 300D (sold)
'12 MINI CooperS Coupe
'71 Triumph Stag
'76 MGB
'08 BMW 535XI wagon
'12 VW Golf TDI

I just used a Mapp gas torch in the hole for about 15-20 seconds and the stuck one I had popped right out

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1982 300D Turbodiesel, daily driver. Mods so far: Fram 8038 paper filter, 4 brake light mod, Gen II w126 (front) rotors/calipers, boost turned up to 12lbs, non-egr manifolds, water/methanol injection, 4-speed manual
1980 300SD Turbodiesel, project car, nearly ready to hit the street

1974 240D, New paint

I have managed to get my stubborn ones out by working around the opening edge with a curved pick. (A decent quality pick, mind, the dollar store ones can break.)

Some shops cut a ridge into the outer ridge of thin needlenose pliers... insert the pliers closed into the opening, then spread them open to catch the seal edge and pull it out.

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

Use a Lag Bolt of the appropriate size. screw it into the heat Seal, grab it with some Vice grips and wiggle it out. A Slide Hammer will work if you can figure out how to attach it to the VG.


Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works