Injector adventures

[apowell@ezlink.com]

My '90 200 now has new fuelish injectors.  Thanks to the group for 
the good info about removing them.  As usual, the challenge was 
getting to the parts...and the damage I caused in doing it.

Dunno about other models, but on my 200, it was necesary to 
remove both the air shroud which cools the injectors, and to 
remove the plate mounted on the top rear end of the manifold.  The 
throttle linkage and cruise actuator both mount on this plate.

Of course, of the three bolts holding on the metal plate, ONE - the 
upper half of which provides the pivot for the throttle linkage - broke 
off in the manifold.  @&*#$^%@#&(@^#.  

Hasn't anyone ever said the words "galvanic corrosion" to the 
honorable Teutonic engineers who designed this????

So - of course I tried using a bolt extractor ("ez out") to remove the 
offending bolt, end, and that extractor of course broke off in the 
bolt.  Now  it was time for inspiration, as I wasn't about to pull the 
manifold and take it to a machine shop.

The broken off unit now consisted of a smooth shaft about 1" long, 
with a nut at the bottom.  Below the nut was about 1/8" of broken 
stub..formerly screwed into the manifold.

Solution:

!)  Clean all pieces thoroughly with denatured alcohol.
2) Cross-drill the broken stub with a tiny bit.
3)  Insert wire thru cross-drilled hole.
4)  Coat bolt hole in mounting plate and base of broken unit 
liberally with JB Weld.  (JB Weld temperature tolerance is 600 
degrees, shear strength is 3900 psi.)
5)  Pull wires thru hole to seat part as firmly as possible into JB 
weld on mounting plate - leave wires in place for extra securing 
power.  Let it cure.

16 hours later, the JB weld holds the throttle pivot firmly and 
securely in place; the plate has been re-installed with two bolts 
(minus the broken off one), and the car starts much more easily.  
Boh mounting bolts were treated carefully with anti-sieze  to 
minimize the chance of a bolt problem if removal is ever necessary.

Another day in the life of an Audi hobbyist.
++++++++++++++++++++WSU-CSU+++++++++++++++++
Al Powell
Apowell@EZlink.com
1958 Fiat 1200 Spyder "Transformabile"
1983 Datsun 280ZXT
1990 Audi 200
http://www.ezlink.com/~powells/
++++++++++++++++++++++++++++++++++++++++++++++