Broken plastic injector inserts 1983 Campaign 1.8 GTI DX

Howdy folks,

Hope you can help. my 1983 GTI Campaign 1800 DX suffered a blown head gasket a couple of months ago. I sent the head of to the machine shop and have received back a fully re-built cylinder head,

However when I collected the head I noticed they had not removed the plastic injector inserts shrouds. I have tried to remove the inserts using the correct 12mm hex allen key at the weekend, but as they are so brittle I have managed to round of the edges. I am scared of bits of plastic going into the engine and would really like to insert a fresh set before putting on the head.

Can anyone give any advice on what would be the easiest way to remove them?

I was thinking of putting a rag or an old sock underneath and tapping the insert with a screwdriver.

Much appreciated

Muller 

Resurrecting an old post - I'm in the same situation. Rounded injector inserts. Lots of swear words. Narrowly avoided hissy fit.

Any advice welcome!!

There's a few old posts available on here, do a search. One of them used a long bolt, washer and nut an levered them. There was a suggestion brass ones would be better and also that there are two types available. Long and short.

Vic said

There's a few old posts available on here, do a search. One of them used a long bolt, washer and nut an levered them. There was a suggestion brass ones would be better and also that there are two types available. Long and short.

Shrouded and unshrouded injector nozzles are what we call them over here.

As I don't see the vacuum take off on the head I would assume they are unshrouded.

I have heard of folks Taking then out by breakage, then using a vacuum hose through the spark plug hole and or the exhaust port sucking the bits that have fallen out of the cylinders, but it is way easier to remove them with out the head attached to the engine, and you don't have to worry about contamination….. Mark this down to 20-20 hindsight.

Vic said

There's a few old posts available on here, do a search. One of them used a long bolt, washer and nut an levered them. There was a suggestion brass ones would be better and also that there are two types available. Long and short.

Thanks Vic - i've searched 3 or 4 similar posts before posting but obviously need to look harder.

Briano1234 said

Vic said

There's a few old posts available on here, do a search. One of them used a long bolt, washer and nut an levered them. There was a suggestion brass ones would be better and also that there are two types available. Long and short.

Shrouded and unshrouded injector nozzles are what we call them over here.

As I don't see the vacuum take off on the head I would assume they are unshrouded.

I have heard of folks Taking then out by breakage, then using a vacuum hose through the spark plug hole and or the exhaust port sucking the bits that have fallen out of the cylinders, but it is way easier to remove them with out the head attached to the engine, and you don't have to worry about contamination….. Mark this down to 20-20 hindsight.

Thanks Briano,

Above photos are from an old post by someone else, but ill be sure to verify the type when i get them out, before replacing.

The head is off, and along with the block is stripped down ready for rebuild, so current plan is to carefully break them down using my dremel.