Procedure for replacing your 88 5kq fuel injector inserts/seals

[Jan Pinkowish]

-----Original Message-----
Message: 2
Date: Wed, 06 Sep 2006 23:34:05 -0400
From: SJ <syljay at optonline.net>
Subject: Re: 88 5kq - Intermittant Hard Starting

I am reposting because I got no replies to my Labor Day weekend post. I
forgot that you were all down on the beach drinking beer and chasing women
this entire weekend.

<major snipage>

Questions:
Maybe its possible that the #3 fuel injector seals shift and develop a
larger leak under different temperature conditions?
Maybe another injector also leaks under "ideal" conditions and this makes
the A/F too lean for engine to start?

I want to take out all the injectors, check them out, and replace all the
seals. Car has 170k on it. Original injectors.
I also want to remove the fuel injector inserts as these have seals also.
Is the job easier if I remove the intake manifold?
Can the intake manifold(old rounded style) be removed without taking off the
head? Bentley does not help here.
Is it simpler to just remove the head and do the work on the bench?
Is there a kit for all the seals and O rings?

I've read horror stories about dropping the insert plastic parts inside the
head.
I need some BTDT advice and tricks for this R&R job.

SJ

<><><>
I was drinking some beer, but lapping valves and not women.

The injector seals get hard with use/age.  The engine vibrates and the injectors shift ever so slightly and the seal is no longer completely tight.

I just replaced the injectors, lower plastic inserts, and injector seals on my 4kq.  My head and intake manifold are the same as yours.  Injectors are the same design; yours just have the fine threads.

Here are my comments/suggestions:
--Removing the head is a gigantic pain and will cost you $$ for a new head gasket and prolly some other gaskets.  Do this job with the head on the engine.
--Get yourself a fuel injector removal tool.  They are on ebay for $11.  Use "audi fuel injector" or "VW fuel injector" as the search wildcard.  Same tool.  It works well and will save your swear words for more deserving occasions.  The tool works with a blade screwdriver.  Use a formed piece of aluminum under the screwdriver to protect the valve cover.

--There are no injector seal kits.  You should also replace the lower plastic inserts.  Here are the part numbers:

035 133 554     lower plastic injector insert
035 133 557     seal for lower plastic insert
035 133 557A   lower seal for silver injector cap
034 133 557E   upper seal for injector(green Viton doughnut)

Get an extra of the two injector seals.  Total should be under $20US.

--If your fuel mileage is acceptable, reuse the injectors.  If not, you can replace the injectors.  New injectors come with the upper and lower seals.  

--You can reuse the upper brass inserts.  Bentley tells you to use a 13mm allen tool to remove the upper brass inserts.  A 1/2" is 12.7mm and works.  Just turn slowly.  If you can find a 1/2" or 13mm Allen socket that's wonderful.  Otherwise, you will have to remove the valve cover for the 1/2" allen tool.  The brass inserts will prolly be tough to remove.  Pull hard, but smoothly and slowly for the first complete turn.  The lower plastic inserts/gaskets are prolly stuck to the head.

--If the lower plastic inserts remain in the head when you remove the brass inserts, you can remove them by screwing in a 1/2 x 13 tap a few turns and GENTLY wiggling and pulling.  I did this with success.  The plastic inserts came out whole.  This is a very good trick.

--Use a dental pick to remove the remainder of the lower insert gasket from the head.  You'll also need a mirror and light.  If you're concerned about dropping bits of the gasket into the intake chamber, you could fashion a suction tube out of a plastic straw taped to your vacuum cleaner tool.  Now you're playing dentist.

--Cut off the old injector seals.  Soak the new seals in gas while you're removing the old seals.  Use a plastic tip from a caulking tube to install the new green Viton seals.  Cut the tip so that it just fits over the cap end of the injector.

--The lower plastic insert just snaps onto the brass insert.

In fact, go to the SJM Autotechnik page for more injector seal installation tips and diagrams:

http://www.sjmautotechnik.com/trouble_shooting/injector.html#inject

You could buy your parts from Scott.  

--Reinstall the assembled inserts and use blue thread locker
--Put the injectors back on the fuel lines
--Coat the injector seals with gas and pop each injector back into its brass insert.

Das it.

HTH

Jan Pinkowish