Injector thread broken off on cylinder head (engine). What now?

[meeh85]

Hi.
Greetings from Norway. I will try to explain in english..... And thanks a lot for reading this !!!

I have a 1989 VW T3. It’s supposed to have a 1.9 turbo diesel engine from a Golf (but I’ve never managed to find the engine code). When I bought the car, I had no idea about cars. But I’ve managed quite well with help from YouTube and similar sources.
 This time, however, things went really bad. I haven’t been able to get help through Norwegian forums and groups. I’ve been turned down everywhere by companies I’ve contacted here in Norway.
 The problem:
Diesel started seeping up from underneath one of the injectors. I bought a new injector, removed the old one, and tried to screw in the new one — but two  parts from the engine itself broke off, . Possibly because I used too much force.
 The threaded mount for the injector in the cylinder head is therefore partly gone—enough that I can’t attach it properly at all. Some people mention a Time-Sert thread insert as a possible fix, but I can’t find anything that seems to fit.
 This is far beyond my modest skill level. I honestly have no idea what to do. :/
 Any suggestions? Even a temporary fix would be fine, just so I can drive the car somewhere. If a more complex operation is needed later for a permanent solution, that’s okay too.

Thanks a lot for the help !!! 

[cobblers]

There are only three or four threads left. This might be enough to gently thread a new injector into as a short term fix (to get you home, but no more) but it's not enough to properly hold the injector with full torque.

Realistically, you need to replace the cylinder head.

[davidoft1]

New head is the best and possibly only realistic solution

[R0B]

For those who cant see the images.









 

[Aidan]

New head is the best and possibly only realistic solution

WHS /\ /\ /\ /\ /\ /\

[meeh85]

Thanks for the replies. 

I guess I should not try to replace it myself. ;P And that the head gasket should be replaced as well.

Since i can`t use the car. Maybe it would be more easy to just remove the whole engine, and deliver it to a engine repair shop. Hmm.

[Aidan]

Do you have a decent old school, diesel engine competent, friendly, local garage who'd be prepared to do it ? If so they'd probably be happy to have the vehicle recovered to them and do the head change, with new gasket, and replace the timing belt and check the timing of the pump at the same time.
If not then brace yourself for the learning curve and do it yourself, it's not rocket science and if you can do that you can do anything pretty much on your van going forward.
I thought you were pretty much past oil powered combustion engines in Norway, you almost completely buy electric cars new and a third of the fleet is now electric. We are a long way behind you with that shift, though the Iran war will push more waverers over the edge. I guess it will depend on where in Norway, it's a big country.

[davidoft1]

Thanks for the replies. 

I guess I should not try to replace it myself. ;P And that the head gasket should be replaced as well.

Since i can`t use the car. Maybe it would be more easy to just remove the whole engine, and deliver it to a engine repair shop. Hmm.

How would removing the engine be easier than removing the cylinder head ?

[clift_d]

If it’s a 1.9TD then the chances are you have an AAZ engine from a Mk3 Golf, and it looks to have been fitted with a JX injection pump from a 1.6TD to avoid clearance issues with the engine cover. You’ll be able to confirm this if you can read the code on the engine - it should be stamped of the top edge of the cylinder block to the right of and below the injection pump. As others have said you’ll almost certainly need to replace the cylinder head.

[meeh85]

Do you have a decent old school, diesel engine competent, friendly, local garage who'd be prepared to do it ? If so they'd probably be happy to have the vehicle recovered to them and do the head change, with new gasket, and replace the timing belt and check the timing of the pump at the same time.
If not then brace yourself for the learning curve and do it yourself, it's not rocket science and if you can do that you can do anything pretty much on your van going forward.
I thought you were pretty much past oil powered combustion engines in Norway, you almost completely buy electric cars new and a third of the fleet is now electric. We are a long way behind you with that shift, though the Iran war will push more waverers over the edge. I guess it will depend on where in Norway, it's a big country.

Hi Aidan, and thanks for your reply.
Yes and no. I live quite remote; in a area with many busy farmes. So even the knowledge is here... they are so busy with their own equipment that its not time for me. But I have spread the word. So who knows. 

I do have a small garage. So I have been thinking about doing it myself - sloooooowly. The question is if I have enough faith in myself to try.

And yes; I read in the news.... that last year, it was sold 43 (!) new fossil cars in Norway. And so far this year, 16 new fossil cars. :p Close to 100% of new cars in Norway, is now electric. You wrote that a third of the car fleet we have is electric. Last year; we hit the 50% mark on that. So more then half is now electric.

Thanks again for your reply.