injector inserts [long]

[Nigel Heron <scirocco@psycode.com>]

hey guys,

well i decided to change my injector inserts yesterday, here's how it
went ...
Since i had a new port matched intake manifold waiting with a Neuspeed
throttle body on it, i removed the intake manifold, it took forever
'cause one of the hex bolts got rounded, so what i did was remove all
the other bolts and then pivoted the intake around the last bolt to
loosen it up a bit, then grabbed it with vise grips. Once that was off i
shoved rages in the intake ports to catch any falling crap. Using vise
grips and a crowbar i yanked out the injectors... then disaster, i
completely destroyed the last injector, broke it in half.. but at least
it came out (luckily i had some more spares from my other rocco, so it
wasn't really a problem). The injector inserts came out pretty easily as
did the seals (i just cut up the old seals with pliers). Using brake
cleaner and compressed air i cleaned the injector holes in the head and
the air shroud port (the air shroud on this '85 head is different than
the one on my '86, it's a bolted on piece of plastic instead of a metal
port that is cast into the head on the 86). I soaked the new seals in
gas and put the special loctite 620 goop on the new brass inserts and
screwed them in. The seals on the injectors were a bit of a pain to get
on but soaking them in gas helped alot. The new manifold went on easy
but the stupid throttle cable came off the pedal, so i had to remove the
lower dash panel to put it back on.

after all that i checked my O2 sensor, it was doing the usual voltage
limbo. Then i checked the idle mixture, it moved from about 45 (i set it
on sunday) to 52 dwell .. so the injector seals must have been leaking
air! The idle is SO steady now, the needle looks like it was nailed to
the background!! .. oh, i also cleaned out the aux air valve which might
have helped.

well, since i have the crappy single exhaust manifold i didn't expect
much gain.. and i didn't notice any, but part throttle response is
better. The sound changed too a bit, kinda' like when you gut the
airbox. The thing that impressed me the most though was the feeling of
the new throttle body linkage .. feels very tight .. i love it. I would
recommend that anyone with a mushy gas pedal to change the throttle
springs, it feels great.


the only thing i would do differently next time, is to buy that special
tool for pulling injectors.. it was the hardest part of the job. I would
also put something under the gas pedal so that the cable doesn't come
loose.

i'll be doing an injector purge this week-end (my friend just bough the
super-dupper Lubro Moly injection cleaner system, it looks like a big
fire extinguisher with a hand pump on it, you just run your car on the
bottle instead of the gas tank, it lasts about 20 minutes!!!), i'll let
you guys know how it goes.

-nigel.
86 Scirocco
85 Scirocco
http://scirocco.psycode.com/


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