Quick how to on replacing Injectors in a CI-System
 

HI all,

With all Mike's great work in developing HOW-to's here's one for replacing the Injectors in the Mechanical CI System (K-Jet).

Time required: 30mins

Parts required:

1 * 10mm Socket head and long reach ratchet .
1 * 12mm open ended spanner
1 * 14mm open ended spanner

4 * Bosch injectors ( part 0 437 502 015)
4 * Small injector rings
4 * Plastic Cups
4 * Large Cup rings


( I got all the above injector parts from FCP Groton on Ebay )

Steps:

1. The Night before I sprayed a little Plus-Gas on each of the hold-down bolts ( see pic2) to ensure they were free.

2. Pre-assemble the small rubber rings onto the injectors and install the large rings onto the Cups as per Pic 1 ( I left the large ring off so you can see where it goes. ) .

3.Then install the injector into its Cup there should be a click as the injector's rubber ring fits into the receptacle in the Cup

4. Using the 10mm socket remove the bolt securing the plastic cup and you may have to use a flat-blade screwdriver to lever the cup out of its place.

5. Using the 12mm spanner on the injector and the 14mm spanner on the other section loosen and remove the injector.

6. Now install the new injector assembly to the feed pipe reverse of step 5.

7. Insert the injector cup assembly into the engine block and tighten down using the bolt removed in step 4

7. Check all bolts are tighten down properly.

8. Startup the car and check for any leaks.

After doing mine there was a noticeable change in the engine tone ,less hunting and there feels like there's more pull( but that could be all in my mind :- ) ).


Pic 3 is of the old injectors

hope this helps someone

regards

brendan

Thanks for that one! The engne will almost certainly run better - usually the o rings are past there best and air is leaking in around them.

A small pry bar is better than a screwdriver to lever them out - some can be stuck well in and may break.

Mike

Hi Brendan, many thanks for that. Just wondered what symptoms you were getting which caused you to change the injectors? Also, how expensive were the parts? Thanks, John.

Thanks brens-s80. I replaced my rubber 'washers' on my injectors a couple of years ago, due to running problems. Mine spluttered when accelerating & had a lack of umph (yes difficult to notice in a 2.0ltr LOL).

Just replacing the seals made a big difference. I diagnosed (with direction from Paul Clifton) my problem by spraying carb cleaner onto the injectors & listening for a change in engine note.

When I removed them the thinner of the two seals just fell to pieces, they had perished that much!

I think you've 'spurred' me on to changing mine though as they must be somewhat blocked after nigh on 20 years.........

Cheers.

hi
 

Hi John.

I must admit I had no real symptons other than the injectors being insitu for the last 20years so i reckoned it was time for a clean out or swap.

But when I took out injector 4 the outer ring on the cup was all distorted and crumbled away.

Prices weren't 2 bad iirc about $220 shipped and with the exchange rate the way it is it made sense as the dealer wanted nearly 80euros per injector and seals.

regards

brendn

Great guide Brendan, thanks for posting!

Ian