924Board.org

The Fife · Joined: 17 Mar 2004 Posts: 241 Location: San Antonio, Texas

It looks just like new! I can definitely recommend a place over here in San Antonio if anybody is in the area. Now the problem is that I have the head, and gaskets, but not the tools and belts... I just have to resist the urge to put things back together but since I don't have the alternator/ac belt I wouldn't be able to drive anywhere anyway. Besides, I still need to check out the water pump (which requires some of those tools...) before I can put anything back together anyway. And probably clean out the injectors since that'd be a good idea.

How do you get the fuel injectors off the intake manifold? Any tips on cleaning them? Are those o-rings a standard size that I could pick up locally, or is that another part specific to these cars?

Sleykin · Posted: Sat Oct 02, 2004 8:06 am Post subject:

The injectors just pull out. The fuel rail holds them in place and they are held onto the rail with clips. The should have come off with the fuel rail.
You need to get the injector seal kits .. about $3 a pop. They are common to a lot of Bosch injectors so should be no trouble getting them. You could just replace the O rings but then you can't back flush them very easily without taking the plastic caps off and the caps are not reusable.
To clean them I used a piece of clear hose about a foot long that fit nicely on the injectors. I filled the hose with injector cleaner (or alcohol or laquer thinner) and used the aircompressor to pressurize the hose. To fire the injectors I used a 9V battery. You don't want to use a full 12 V or high current source as it can fry them. Back flush a couple times first and then blow it through the right way and check the pattern. Be careful not to ding the exposed tip when the caps are off. They have an inlet screen that need to be looked at to be sure it got de-gunked. I found no reasonable way to pull the screens out without destroying them so the back flush is mostly to clean the screens. Soaking a couple hours first would be a good idea to loosen things up a bit.
Only tricky part is to get enough pressure to clean them without blowing the hose off

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Glenn Neff
Medford, OR
87' 924S

The Fife · Joined: 17 Mar 2004 Posts: 241 Location: San Antonio, Texas

I remember when I was taking the fuel rail off I couldn't separate the fuel rail from the injectors/intake without undoing the clips. This afternoon I've been tugging on the injectors pretty hard but something tells me they're not supposed to be in that tight. It's like the orange piece is keeping them stuck in the intake manifold or something?

Sleykin · Posted: Sat Oct 02, 2004 9:57 am Post subject:

Spray some WD40 or such on them ... they are glued in from varnish and hard O rings. Mine came out fairly easy with the rail. There is a groove inside the intake that sorta hold em and the hard rings make it ... hard

They just pull out though. Might have to come up with something to go around the big part to pry on ... got a valve spring sompressor for an L head??

(or lawnmower) ...
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Glenn Neff
Medford, OR
87' 924S

The Fife · Joined: 17 Mar 2004 Posts: 241 Location: San Antonio, Texas

I'll have to give WD-40 a try. It'll have plenty of time to soak while I do other things. From the way the writeup was on Clark's Garage I thought they'd just fall right out or something. I didn't know there was another o-ring down in there keeping things in. Is it possible to push them out from the nozzle end without damaging them? I'd rather be safe than have to go find new injectors!

Sleykin · Posted: Sun Oct 03, 2004 8:36 am Post subject:

The nozzel end is pretty fragile. They will pull out. Just have to get the O rings softened up enough to squish past the groove. Can you twist em around? They should turn freely. Might have to put the rail back on with the clips and pull em out with that?
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Glenn Neff
Medford, OR
87' 924S

The Fife · Joined: 17 Mar 2004 Posts: 241 Location: San Antonio, Texas

Still soaking... looks like this might take awhile.

Sleykin · Posted: Sun Oct 03, 2004 3:11 pm Post subject:

Try something meaner. Laquer thinner or paint thinner os something that will attack the O ring. I can't feature why they won't come out easier ... I have pulled a lot of injectors out of a lot of different motors and the 924S was no different than any other electric injectors.
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Glenn Neff
Medford, OR
87' 924S

garthfan · Joined: 28 Feb 2004 Posts: 226 Location: Manchester, NH

If it helps...I just pulled my injectors the other day in the course of this rebuild I'm doing. I had a hard time getting two of them out as well but a good pair of plug-wire pullers did the trick. They allow you to grab ahold of the body and get a nice, even pull on them without damaging anything. Good luck!
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1987 924S - Was a daily driver...now it's GONE! *sniff*
1986 944 N/A Guards Red
1996 VW Jetta Grocery-Getter
1995 Saab 900S Winter-Driving-Feeling-of-Security-Vehicle

The Fife · Joined: 17 Mar 2004 Posts: 241 Location: San Antonio, Texas

I've gotten one of them out finally. Wrapping a rag around it helps, but I didn't put tons of force on it (don't want to damage one). They're pretty dirty and I'm not sure how to get the orange cap off quite yet.

pyromjm · Joined: 26 Sep 2003 Posts: 154 Location: Cupertino, CA USA

I pulled out all of my injectors and put them in a container to catch the spray. 2 of them are leaking before they start spraying, and all 4 have terrible spray patterns. If i soak them in the injector cleaner like someone suggested will that help? or if theyre leaking is all hope lost and i need to buy new ones?
-Mike
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1982 924 NA gray/silver with black int.