Injector stuck in Ford Transit cylinder head - what to do?

Seized injectors are a curse of the 2.2 and 2.4 TDCi engines. Carbon build-up and corrosion can lock the injector in its seat so hard that removal requires a hydraulic puller, and in extreme cases the injector comes out in pieces. Workshops usually charge a few hundred zlotys per injector for extraction. Prevention is the key: whenever work is done on the injectors, the seats should be cleaned with a seat cutter, the injector body coated with ceramic paste, and the copper washer and seals replaced with new ones. After fitting a new or reconditioned injector, the C2I code must be programmed into the ECU; without coding, the engine runs unevenly and smokes.