cleaning out cis fuel distributor

[rgmrgm]

Plunger in the fuel distributor was stuck, i tried soaking it with carb cleaner, tried to grab it and pull it out, no luck so i took it apart. I had to beat the plunger out with a wooden dowel and a plastic hammer, bottom half of the fuel distributor was spotless so was the bottom of the thin steel plate, top was covered with old gas varnish and rust. weanted to replace all the o-rings, 6 small and two larger ones, but couldn't find exact size o-rings, went to a gasket and seal specialty shop and they measured the old ones and they are neither standard nor metric. got some that were close, cleaned all the small filters and passages and cleaned the plunger and bore with a brass brush and carb cleaner. put it back together and it seems to work fine w/no leaks. i noticed the plunger had the number "2" etched on it but couldn't find a number on the bore. with the plunger half way in the bore there is no lateral movement that my dial indicator could measure, pretty tight fit. if you do try to take one apart make sure you identify the orientation of the plunger bore before removing, it can go in six different ways. plunger and bore cleaned up nicely no rust. use oil on the o-rings as they must pass a knife edge before seating.

[CharlieB]

Wow!! The planets really are aligned for you. Good job!

[E Sully]

I took a picture of the notch in the plunger bore before taking it apart to make sure it aligned when I reassembled.

[T77911S]

the plunger bore, that was what i was waiting to read about. like you have found out, that has to be lined up perfectly.
the 6 slits have to line up to the 6 chambers.

the FD can be partially taken apart without removing the plunger bore, which is best, but in your case, trying to get the plunger out was a bit harder.

i dont know for sure but i assume the notches in the plunger bore, in the pic, are used by a tool to not only hold it but to line up the slits to the chambers.

[rgmrgm]

if you notice the plunger bore has a very small hole in addition to the six ports, the housing also has a similar hole, those holes are not lined up but are about 180 degrees out of alignment

[T77911S]

i dont remember, but i have not opened on in a while. i was looking at one out of a mercedes a while back thinking that one was even more different than the 911's, but it was out of a 90 i think, 300E.