Fuel Injector Inserts

[QSHIPQ@aol.com]

Since I had given Phil the wrong size sometime back, let me somewhat redeem
myself with the correct size for the Injector Seats.  You need a 13mm Hex for
the removal of same.  Finding this might be easier than you think.  Some of
the cheaper triple squares use the 13mm Hex as the driver size.  Flipping it
upside down with a long 13mm socket attached can save you some big money for
this job.  

So, pull the FI's (12mm and 14mm flare wrenches), insert the hex into the
seat and extract.  There is an flat o-ring that you will want to replace on
insertion, a common (and cheap) vw/audi Part # 035 133 557.  Make sure you
have removed 5 before you insert 5.  I find that most stick to the insert,
but some remain in the head on occasion (a dental pick gets those).  Clean
the Upper Insert (034 133 555 A - air shrouded injectors only) and the Lower
Insert (034 133 554 - air shrouded injectors only) with carb cleaner, inside
and out, before install.  You don't need to replace either unless damaged.
 The lower plastic insert snaps onto the upper brass one, and you want to
check the plastic for any cracks.  The torque spec seems high on the insert
per Bentley, but is correct.

Make sure you buy the Viton (green) upper injector seals from the dealer,
most aftermarket (including the bosch O-ring replacement kits) are NOT the
Viton type, and crack easily with the turbo heat cycles.  If you are
replacing the whole injector with new, the new DO come with the Viton already
on.  

Helpful Hint (hello Mr. Goggin):  On insertion of injector with air shrouds
(upper and lower seal), lightly coat the lower seal with oil, and twist the
injector gently into it's seated position.  You can easily lose the lower
seal if you neglect this procedure, and all your "sealing" efforts wasted in
deference to the air leak around the injector that is missing the 0-ring.

...  And Phil has a 19mm hex for sale (sorry 'bout that Phil).

HTH

Scott Justusson
QSHIPQ@aol.com
'87 5ktqw
'84 Urq
'85 FJ1387