3.2 Carrera: Removing Injectors?

[WydRyd]

I have a strong suspicion I have a leaky injector in my left bank and am looking at removing/replacing the suspect injector asap.

Any words of wisdom for a first timer doing this job?

I guess I just need to be careful not to mix up the wiring, but I'll label each one as I remove it from the injector.

Is there a standard process for doing this job easily?

[dfink]

Just did this on my 85'. It can be done with the air box in place but not sure with your turbo what all will be in the way.
left side take off the 2 bolts holding the bracket for the impluse sensors, remove the fuel connectors from both ends of the rail, remove the 2 bolts holding the rail, in my case I removed the injectors wires just by firmly tugging them off the injectors I then removed the metal clips holding the rail to the injectors and pulled up on the rail. Some times the injectors came with the rail sometimes they stayed in the intake. Just wiggle a bit while pulling straight out and they should come right out. You might vacuum aroung the base of the injectors first to remove any dirt so it doesn't fall into the intake. You will also need to remove the retainer loop that holds the main harness wire.
Repeat on the right only no need for the retainer clip.
If like mine the front uses a 15mm on the pressure regulator and 19 on the rail the rear uses a 17 on the hose and a 19 on the rail.

I used compressed air and blew through into the input of the injector to test for leaks. None of mine leaked at the injector but they were leaking around the shaft. There is a thread I have going on now about replacment injectors. I have not been able to find a direct replacement for the bosch others have said they have. With the turbo maybe you want a bit more than the stock injectors.

[dfink]

Injector thread

replacement injectors

[WydRyd]

Thanks for the detailed explanation

I actually run 951 turbo injectors at higher rail pressures.

[WydRyd]

If I just have to replace the #1 injector, is there a quick and easy way to remove & replace it without unbolting the front & rear fuel lines etc?

[stlrj]

In a word, yes. Just remove the 10mm bolts that hold the rail down including the one(s) in back and pull the rail back enough to remove #1.

You can pull all the injectors that way too.

Cheers,

Joe

[WydRyd]

Thanks Joe... I decided to rip them ALL out and send them for ultrasonic cleaning and flow testing tomorrow. $20 per injector

[alniki]

Joe and Merv,

I tried to move injectors #1, #2, #3 by just removing the two 10mm bolts that hold the rail down and pulling the rail back but found it's hardly movable without disconnecting the fuel connectors from both ends of the rail. I dare not use much force pulling the rail as the front end fuel connector (near #3 injector) is so close to the fuel pressure regulator that I could either kink it or damage the end and its thread on the regulator.

I guess I can only do it the way dfink described. Any comment? Thanks!

[dfink]

Your gonna have to disconnect the fuel lines and for the left bank you will need to disconnect the bracket that holds the reference sensors. It seems like more work than it is. Maybe 15 minutes but make sure you use "2" wrenches to loosen the fuel lines.

[WydRyd]

Yeah, you MUST unscrew and remove the fuel lines from both end of the fuel rails to be able to remove the injectors. They just pop out. You do have to use a little force though.

[alniki]

Thank dfink!

Without removing the sensor bracket it's very difficult even to remove the adjacent 10mm bolt.

I did ponder over whether I can do it with only one wrench without disrupting the opposite end but decided it's just too risky so I'll go the two-wrench way!!