Help Modifying Bosch 1600cc Injectors

[RETed]

I dunno if it qualifies as a "pintle cap" since it's a small (yellow?) cap that barely cover the tip?
The pintle cap I'm used to is a cover that covers the entire tip all the way up to the metal fuel injector body...

Anyways, yes, I pop that off and throw it away.
Some people will try and keep this cap - sorta - by shaving the edges so it fits in the holes - I don't like to bother with such trouble.

The key to making this whole thing work is you have to keep the "air bleed valves" that are stock to our engines.
This helps prop up the lower grommets in the holes properly.


-Ted

[My5ABaby]

Gotcha. I tried to pull it off but it wasn't complying. Pull harder i guess.

[RETed]

Yeah, it's stuck on there pretty good.
Just be careful with the "center pin" of the fuel injector tip - don't damage that.
I usually get a sturdy set of pliers and twist it off.


-Ted

[My5ABaby]

As a follow up, I found it easiest and best to use S5 pintle caps with stock spacers on the bottom. On the first injector I sawed through the top plastic horizontally and vertically with a hacksaw. On the second injector I sawed through the top plastic horizontally and then used a soldering iron to melt it vertically and it just popped off - much easier method. I sealed the top part of the injector to the rails with 3 stock o-rings on each.

[My5ABaby]

Well this worked well for a while. I found a small leak coming from the top of one of my injectors. Any thoughts on how to seal the top better? It has 3 new o-rings and still leaks some... :-/

[RETed]

You either got a nicked o-ring, or the fuel rail has a groove in it?

Did you check to see if there is "crud" inside the fuel rail?
Sometimes high-mileage fuel rails can get deposits stuck on the inside walls.
You have to be very careful trying to clean this stuff out...


-Ted

[My5ABaby]

Thanks Ted, I'll take a look.

Ugh these things are annoying. I should have sprang for ID2ks.