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Injector blow-by on a Volvo Penta 2002 engine occurs when combustion gases escape past the injector sleeve, scouring the metal and eventually causing compression loss, vibration, and power reduction.1:32 Symptoms typically begin as a faint "tss" noise that intensifies over time.2:03 Temporary field repairs include the "hammer and spanner" method, which involves tapping the injector to reseat it, or fabricating custom copper washers from annealed copper pipe to seal the gap.2:23 To anneal copper, heat the material until it glows cherry red and quench it in water to soften the metal for deformation.5:47

The only permanent repair requires replacing the injector sleeve.9:32 Owners can hire a specialist, purchase specialized tools to perform the replacement in-situ, or adopt a hybrid approach by removing the cylinder head and bringing it to a professional for the sleeve replacement.9:44 To prepare for this, close the engine intake and sail drive seacocks, drain the cooling system, and remove the cylinder head following a specific loosening sequence to prevent cracking the cast iron.13:19

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