Call us for a fast response for emergency callout requests and to book a fuel injector removal at a time to suit you.

What’s causing these problems?

Carbon related failures have become increasingly common on modern day diesel vehicles due to injector design changes because of EURO regulations that require many technological advancements

Although this is currently a major contributing factor, seal failure issues have existed over the years and many older vehicles also suffer from these problems due to design issues.

Unfortunately, many mechanics overlook seal related failures on diesel vehicles which often means many jobs we see display signs that a seal failure has been ongoing for several months, sometimes for over a year

What are the signs to look out for?

Signs that your injector seals are failing or that carbon has already started to push its way up past the injector seal and up around your injectors are:

  • A smell in the cabin while you are driving that smells like an exhaust leak
  • Louder engine operation than usual
  • Repeated sounds of ‘psst-psst-psst’ from around the injectors.
  • Presence of a black oil/tar like substance around your injectors and on the cam-cover
  • Increased fuel consumption
  • Lack of power
  • Smoke seeping from under the bonnet when the engine is hot

On some occasions we see vehicles that have extremely bad carbon build-up around the injectors and above the cam cover that are invisible to the naked eye – affecting the injectors or the wiring and common rail piping that enters to them.
In these circumstances a mechanic would typically write off the engine or cylinder head and injectors, but we disagree with that practice.

What makes us different?

Our method is to manually, but carefully, extract all carbon from the top of the engine, then use special extraction equipment to remove the injectors. This process allows us to avoid unnecessary expense and vehicle time off the road for our customers.
Once the injectors are out, we inspect them and if suitable for re-use, we recut the sealing and replace the seals on the injectors and re-install them with a 1-year warranty.

Here are a few other services we offer

  • Mercedes (broken in cylinder head) inlet manifold bolts removal
  • BMW 316i E90, E91 seized timing chain tensioner bolt removal
  • VW, Audi, Seat and Skoda 1.6 TDI, 2.0 TDI broken injector clamp bolt removal
  • Vauxhall Movano, Vivaro 2.5 CDTI, 2.0 CDTI seized or broken injector bolts removal

Our expertise isn’t limited to this list, so if your model is not listed call us with your vehicle details and we’ll be able to assist.

The common vehicles suffering from these issues are:


500: 1.3 JTD
Punto/Grande Punto: 1.3 JTD
Panda: 1.3 JTD


1 Series: 118d, 120d, 123d
3 Series: 316d, 318d, 320d, 325d, 328d, 330d, 335d
5 Series: 520d, 525d, 530d, 535d
6 Series: 635d
7 Series: 730d, 740d, 745d
X Series: X1 18d, X1 20d, X1 23d, X3 20d, X3 30d, X5 30d, X5 40d, X6 30d, X6 40d


Mazda2: 1.6 MZ-CD
Mazda3: 1.6 MZ-CD


X-Type: 2.0 TDD


S40: 1.6D
S60: 1.6D
S80: 1.6D
V50: 1.6D
V60: 1.6D
V70: 1.6D
C30: 1.6D


Combo: 1.3 CDTI, 1.7 CDTI
Astra: 1.3 CDTI, 1.7 CDTI
Corsa: 1.3 CDTI, 1.7 CDTI
Zafira: 1.3 CDTI, 1.7 CDTI
Vivaro: 1.9 CDTI, 2.5 DCi
Movano: 2.2 CDTI, 2.5 CDTI


Clio: 1.5 DCi
Megane: 1.5 DCi, 1.9 DCi
Scenic: 1.5 DCi, 1.9 DCi
Kangoo: 1.5 DCI
Trafic: 1.9 DCi, 2.5 DCi
Master: 2.2 DCi, 2.5 DCi


Berlingo: 1.6 HDI
C2: 1.6 HDI
C3: 1.6 HDI
C4: 1.6 HDI
C5: 1.6 HDI, 2.7 HDI
DS3: 1.6 HDI
DS4: 1.6 HDI
Xsara Picasso: 1.6 HDI
Nemo: 1.3 HDI


Cooper D: 1.6d

All VW, Audi,

Seat and Skoda

Fitted with: 1.6 TDI, 2.0 TDI


Focus: 1.6 TDCI
Fiesta: 1.6 TDCI
Fusion: 1.6 TDCI
C-Max: 1.6 TDCI, 2.0 TDCI
S-Max: 1.6 TDCI, 2.0 TDCI
Galaxy: 2.0 TDCI
Transit: 2.0 TDCI, 2.2 TDCI, 2.4 TDCI
Tourneo: 2.0 TDCI, 2.2 TDCI, 2.4 TDCI


A Class: A160 CDI, A170 CDI, A180 CDI, A200 CDI
B Class: B180 CDI, B200 CDI
C/CLC/CLS Class: C200 CDI, C220 CDI, C250 CDI, C300 CDI, C320 CDI, C350 CDI, CLC200 CDI, CLC220 CDI, CLS350 CDI
E Class: E 200 CDI, E220 CDI, E250 CDI, E270 CDI, E300 CDI, E320 CDI, E350 CDI
G/GL/GLK Class: G350 CDI, GL350 CDI, GL450 CDI, GLK200 CDI, GLK220 CDI, GLK250 CDI, GLK350 CDI
M Class: ML280 CDI, ML300 CDI, ML320 CDI ML350 CDI, ML450 CDI
S Class: S300 CDI, S320 CDI, S350 CDI
Vito: 108 CDI, 109 CDI, 111 CDI, 113 CDI, 115 CDI, 116 CDI, 119 CDI, 120 CDI, 122 CDI
Sprinter: 214 CDI, 311 CDI, 313 CDI, 314 CDI, 316 CDI, 414 CDI, 210 CDI, 213 CDI, 216 CDI, 219 CDI
Viano: 111 CDI, 115 CDI, 2.8 CDI, 3.0 V6 CDI


206: 1.6 HDi
207: 1.6 HDi
307: 1.6 HDi
308: 1.6 HDi
407: 1.6 HDi, 2.7 HDi
508: 1.6 HDi
Bipper: 1.3 HDi