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Old 09-05-2016, 16:48   #1
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How to Extract the copper injector tubes in a Volvo Penta 2000 series diesel

I'm trying to find a way to extract the injector tubes in my Volvo Penta 2002 diesel. I don't have or want to buy the $350.00 volvo tool extraction tool.
If any one else tried and succeeded somehow, I'd like to know.
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Old 09-05-2016, 16:58   #2
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Re: How to Extract the copper injector tubes in a Volvo Penta 2000 series diesel

Have you pulled the head? I don't remember getting them out as that tough once the head was out. We used an old injector as a template to have tool turned to set the new ones.
Are yours leaking fuel or coolant?
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Old 10-05-2016, 03:52   #3
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Re: How to Extract the copper injector tubes in a Volvo Penta 2000 series diesel

I'm rebuilding the engine, as well as new rings, bearings and seals, had the head off and refurbished, ie, the valves ground, the injectors rebuilt, new valve stems and seals. When I put it back together and did a test run, noticed the injector tubes are leaking water on the top of the head. No blowby. I guess I could take the head off but not sure that would make it easier to get the tubes out without the special volvo tool. I guess I'm asking how to make some kind of extracting tool for less money.
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Old 10-05-2016, 08:53   #4
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Re: How to Extract the copper injector tubes in a Volvo Penta 2000 series diesel

Found the Official Volvo Puller on line for $175.00 US. Maybe I should bite the bullet. Not getting any advice on an alternate.
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Old 10-05-2016, 14:19   #5
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Re: How to Extract the copper injector tubes in a Volvo Penta 2000 series diesel

Here's a CF thread with a little bit of info on pulling the sleeve without a tool Volvo 2002 injector sleeve fix
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Old 10-05-2016, 14:20   #6
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Re: How to Extract the copper injector tubes in a Volvo Penta 2000 series diesel

Getting them out is easy, just use an appropriately sized drift and hammer them out. If you're uncomfortable with the risk of damaging the head using a drift then tap a 10mm thread into the tube and wind in a 10mm bolt and press them out. Installing them is a different matter as they need to be pressed then swaged and that requires the special tool.
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Old 10-05-2016, 16:52   #7
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Re: How to Extract the copper injector tubes in a Volvo Penta 2000 series diesel

I ordered the tool from Marine Parts Express today ($125.00) along with a new head gasket. I was successful in pulling a tube out a few years back, but these seem more tenaciously locked into the head. As I live in Nova Scotia, it takes time for things to arrive and then there's the low Canadian dollar. Should be good to go in a couple of weeks, it's still pretty chilly here.
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