'73.5 911T CIS injestors

[Flormat]

I would very much like to replace my injector seals and possibly my injectors if it weren't for one problem. The damn things won't come out!!! I can spin them like a top but they won't pop out. I swear I can hear them laughing. The rubber feels like concrete. Anyone know of a way to get these buggers out?

[Zuff911]

Fuel Injector (CIS) removal ASSISTANCE

[Sunroof]

Here is the deal on the injectors as I just finished replacing all six.

The injectors on the 2.4 1973.5T model are set up unlike nothing else! The retainers or metal cup shaped holder's where the rubber bushing goes in are pressed into the cylinders so if you break a large piece off that could be a problem. Always focus on that metal retaining piece as its easy to damage them.

When you disconnect the two nuts locking the fuel line to the injector, fuel will not flow out like Niagra Falls, but keep a jar handy to catch whatever fuel drains from the lines.

It is helpful to disconnect all three on the same side and LABEL THEM CORRECTLY so that you do not damage any line and have ample room to get around in the injector removal process. These plastic fuel lines can be a pain to replace.

The tool sold in catalogs for the injector removal does not work on this car as they are only for the injectors that are seated in the intake manifold units (2.7 on). They provide the wrong angle for this injector to be removed unless someone else has mastered using it. You have to buy or find a nut that will screw on the top of the injector after you disconnect the fuel line and can weld or epoxy on some type of loop on the nut to attach a lanyard to help ease them out. You could also get a nut with oversized washer placed under the nut to help hold a prying device. Thats what I used.

You will need to spray WD40 or some type lubricate (small quantity) around and into the rubber bushing to help soften that very hard, non-pliable aged bushing that will not make it past the lip of the metal retention piece.

Are ya with me?

I bought a pry bar, notched nail puller type device (8 inches or so) at the hardware store to fit underneath the nut and washer and yank slowly but forcefully to get them out. Take a new injector with you and have fun at Home Depot or wherever you like to find tools to set it up. USE A PIECE OF WOOD to rest on the valve cover to provide support and get the right angle to slowly pry them out. You can really rip your knuckes and hands up getting these out, so remember its one at a time and they will come out.

The reason they are turning so easily is because the rubber holding them in is as hard as hell and is not pliable enough to make it past that metal lip without brute force. The metal lip will hold fast, but the outter spill cup area may break off if your not careful.

Once out, you will be amazed at just how easy the new ones go in. Nothing like fresh rubber!!

This was my experience and it was a good half day to get it done.
Take it slow and you will be fine. I hope this helps.

Regards
Bob
73.5T

[Flormat]

Thanks Bob and Zuff. I managed to get one out yesterday by using different prying methods, but apparently I was not prying it as straight as I thought because the injector broke in half. After that the rest of the injector and the rubber seal came out quite easily. I'm thinking about buying new cylinders with the metal sleeves already pressed in! Thanks for the tip, I'll be off the the hardware store to see what I can come up with.

[HarryD]

Interesting. For those of us who are visualization challenged, do you have any pictures of how to go about this job?

[Sunroof]

Sorry Harry.
No photos, just some memories of a pain in the ass project!!
Its really is a simple operation, BUT it gets down to just how hard that rubber seal had become over years of heat-cold-heat-cold.

If you look carefully at the tin type cup that the injector and rubber seal fit into, their is a ridge where the rubber seal must pass to get both the inject and seal out.

When you lubricate the area with WD40, it might be easy to just pry the injector out thru the rubber and that way the rubber gasket can come out easier. Careful though, you do not want rubber pieces falling down into that hole!! I used an exacto knife to slighty cut it so I could pinch it with a needle nose pliers and pull the rubber gasket out.

The installation of new seal and injector is very easy.

So the challenge is how to pry and what to use. That is where your creative juices have to flow.

Bob
73.5T CIS