Injector replacement dos/don’ts

[garment]

Hi Pelicans - scored a sweet deal on a set of new injectors for my ‘83 SC with 165k miles and so will be replacing this weekend. Taking this action as I am chasing a hot start issue and will be running a pressure test of course (also looking at the check valve, the fuel accumulator is new). Any words of wisdom here? I’ve got the metal fuel lines from the distributor. And can I use replacement o-rings from any local auto parts store?

Thanks, Pelicans!

[SalParadise]

You can use o-rings from any auto parts store obviously if they are the same size. I am sure you will be able to find the right size since that size was used on a lot of Bosch injectors.

The metal lines bend pretty easily - but they do not break in my experience, but I would not bend them too much as they will not look right when you place them back. The plastic clips that hold them will probably be more of a hassle - and may need to be replaced.

My advice is to do ONE AT A TIME starting at the back of the motor. Do not pull them all out (it does not matter if you mix them up, but it's easier to control any debris or other things that may drop down in there).

You could use some dish soap to lube up the rings, but usually they pop right in.

As I have constantly said, it's pointless to put yourself through all of this unless the red injector sleeves are also replaced with their o-rings. These red sleeves in the manifolds are way past their service life and are either crumbling, chipping, and not sealing - but this is a much bigger job.

[garment]

Thanks for the info. Yes, my injector sleeves are recently replaced and should be ok for many more miles. Will report back on the results.

Originally Posted by SalParadise

You can use o-rings from any auto parts store obviously if they are the same size. I am sure you will be able to find the right size since that size was used on a lot of Bosch injectors.

The metal lines bend pretty easily - but they do not break in my experience, but I would not bend them too much as they will not look right when you place them back. The plastic clips that hold them will probably be more of a hassle - and may need to be replaced.

My advice is to do ONE AT A TIME starting at the back of the motor. Do not pull them all out (it does not matter if you mix them up, but it's easier to control any debris or other things that may drop down in there).

You could use some dish soap to lube up the rings, but usually they pop right in.

As I have constantly said, it's pointless to put yourself through all of this unless the red injector sleeves are also replaced with their o-rings. These red sleeves in the manifolds are way past their service life and are either crumbling, chipping, and not sealing - but this is a much bigger job.

[Brian Cameron]

Try alcohol on the o-rings, makes them slippery but quickly evaporates so no risk of the injectors popping back out later.

[gazzerr]

It will depend on how easily you can get them to pop out. Mine were crusty enough to the point where the sleeve and the o-ring were basically fused so I had to tap them out on the bench. They fought me enough where I was starting to get debris falling into the cylinder head so I stopped and just removed the whole CIS.

[schoward]

In one case I popped an injector out having replaced the sleeve and seal 5 years prior. I may have held the sleeve down with a flat head screwdriver while I pulled the whole line and injector upward. I did get a little wiggle on the sleeve but it didnt cause an issue and I checked it for leaks after with no issue. Seal was still pliable enough after 5 years it gently popped right out. Maybe a little spray oil alcohol would help. That’s about it.

On injector replacement, I swear the engine felt tighter right after, like the injector spring mechanisms needed to break in. As they are mechanical devices I think that may have been the case (most may disagree). 2 or 3 drives later car felt back to normal, with maybe a little more oomph.

[garment]

New injectors are in, (mostly) without any drama - When I pulled #6, the sleeve came out with it. Seems like it wasn't spiked that well? I just pushed it back in and I'll run with it for the time being. Car does seem a bit peppier...

My o-rings were green, Alstrom I think? Any issue with these?

I don't think there's been any change in my hot start issue. Fuel pump check valve is next on the replacement list.

Here's the injectors I pulled. Any opinion on the visuals? I may send them out for repair if such a service exists?