Diesel Bombers - 6BT and 4BT Injector Removal

Lately I have been getting injector cores back that have had some sort of damage inflicted upon them from being removed from the engine. To try and prevent this in the future and assure that future users of the old injector bodies don't have to worry about the condition of their injectors, I figured I'd point out a few ways to get injectors out easier than using vise grips, channel locks, or a pry bar driectly to the injector.

First here are some pics of bodies I have laying around:

Attachment 41450

Notice the light blue and green circles show teeth marks from vise grips that have been used to wiggle the injector from the injector bore. Also the yellow circle shows where, while removing it, threads were damaged.

Attachment 41451

This injector, at some point in its life was cross threaded in the injection line and also had a pry bar mash the middle two threads.

Attachment 41452

This injector shows all common signs of damage that any injector can. The Yellow circle on the left shows where the threads have been damaged from prying them out of the head. The Blue circles show where the body was damaged on the outside by a pry bar, and if you look closely at the green circle you will see a different kind of damage. The first thread has been stripped out from the return line not being properly lined up when the banjo bolts are installed.

Attachment 41453

This is probably by far one of the worse injectors I have recieved as a core, it won't ever leave the shop other than as scrap. This injector has rusted severely and the nut was stuck on the body and the big groove up the majority of the body and retainer ring is from me cutting the hold down nut off. In the yellow circle you can see how tight I had the vice trying to get the nut off. Also the Blue cirlce shows that when the injector the alignment ball disappeared. These balls are not vital to the injectors functionality just makes it a little harder to align it with the return line.

Attachment 41454

This is a brand new body.

To prevent this, we have found a way to pull injectors out that is simple and cost effective for those that do not need an injector puller. For the P7100 style injectors, take a lugnut off your 94-02 Dodge Pickup, for VE engine take a 12mmX1.50 nut and a fender washer or go to a local parts store and get a lugnut with that thread pitch and a wedge style base, and find a piece of 1" IDX1 1/8" OD pipe and cut it to a little over 1 1/2" in length. Place the pipe over the top of the injector with the hold down nut off the injector. Take the lugnut and screw down on the top of the injectors and it will slowly works its way out easier than using a pair of vise gripes. There may be a time when you get the injector up high enough that it starts to spin in the injector bore because the alignment ball is now out of its slot. This is when you take your pry bar and place it between the pipe and the cylinder head. Applying slight pressure, continue spining the injector until it works free. This will prevent damaging the injectors coming out of the engine.

For those with VP44's its really simple to get injectors out. After removing the hold down, only the front bolt must be removed, the rear bolt never has to be touched as the hold down has a slot in the back that slides into place. Take a VALVE COVER bolt and screw into the top of the injector. Now take a pry bar and place it under the lip of the valve cover bolt head and use the rocker arm to GENTLY pry the injector free. Make sure the connector tube is out before doing this.