I removed my injectors (OM617 - '83 300TD) and had them professionally rebuilt/restored and I want to re-install them. Problem is, only 3 of the five old beveled discs that go in below the injectors came out. Two are still stuck in there. When I removed the injectors they had been way overtightened. Instead of the 90 newton meters torque the specs call for, I had to use a 20" breaker bar with a 24" piece of pipe to break them loose. What's that, 200nm? Who knows, but they were in there. And now I can't get two of the old discs out. I've tried flicking them with a screwdriver and all I've done is nick the center hole up - the discs themselves didn't budge. I left rag corners soaked in solvent stuffed down in there for the last few nights and I'm on my way to try one more time. Any suggestions? Would heat help?

Thank you in advance,

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Will



72 280SEL
85 300CD 288k
00 E320 Wagon 4-matic 100k
11 E350 Wagon 4-matic 45k

73 VW Westfalia Camper
67 VW Westfalia Camper

66 Porsche 912

There's a bunch of threads and posts on this. Here's my soluiton. After some PB Blaster or something similer soaking for a while, I found that if you place a heavy rag or towel over the hole and crank the engine a few seconds, the compression should blast the heat shield out. The rag stops it from shooting out like a bullet. A lot of folks will chime in and say what a horrible method this is. BUT, it works and I cannot see how in the world this causes a problem. Make sure the hole is cleaned out because you dont want any junk going down the hole....

I'll give it a try. Thanks!

On those stubborn carbon packed heat shields, one trick that has always worked for me is to take a 1/4" dia flat face punch and a hammer, tap all around the outer diameter of the heat shield. This breaks up the carbon and the heat shield comes out easily with a magnet or a hook. No solvents needed.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I will try that. Today I tried the turn the engine over some method and it had no effect. I'm actually kind of mystified as to how compression pressure could build behind the heat shield being that it has a 1/4" hole in the center of it. Anyway, again, it had no effect. I have tapped on it some trying to jar it but not earnestly with a punch that size. I'll try that next. I did also leave it today with a rag corner stuffed in the hole and then PB Blaster pooled around that.

Thanks!

__________________
Will



72 280SEL
85 300CD 288k
00 E320 Wagon 4-matic 100k
11 E350 Wagon 4-matic 45k

73 VW Westfalia Camper
67 VW Westfalia Camper

66 Porsche 912

I usually stick a 3/8" long extension down there and give it a kiss with a 3lb persuader.

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1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge