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PostPosted: Wed Jan 29, 2014 10:50 pm 
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Location: Camberley, Surrey
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Hi Folks,

What if any parts will I need in order to replace the fuel injectors, are there any seals etc that should really be changed. The injectors I am fitting are brand new Sard/Denso 800cc items.

Also - does anyone have a 'how-to' for doing this work with the engine in the car.

Cheers :)

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PostPosted: Wed Jan 29, 2014 11:12 pm 
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See the sticky on part numbers mike replace all seals IMHO

Employ the laziest person to do the most difficult job and they will find the most efficient way of doing it!

I found that you can remove the fuel rail and twiddle it to replace injectors - circa 1 hour job

Or remove fuel rail from engine like most will and it takes 8 hours hard graft.

IIRC the chargecooler needs to be removed and the throttle body is much easier to remove.

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PostPosted: Thu Jan 30, 2014 12:57 am 
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Unbolt the loom from the inlet too iirc


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PostPosted: Thu Jan 30, 2014 6:02 pm 
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Mike,
1) the injectors if new are prone to being "sticky" use a 12v car battery and 2 pieces of wire to check they are working OK before fitting and to give them an initial kick into life. Just very briefly touch the injector terminals with the wires to open & shut them (you will hear a faint click). If you remember correctly when we fitted mine at K&Ls I had a sticky injector or 4 as they had been sat on the shelf for a while.

2) why not get the ECU fitter to install them - IIRC most places will charge around £75 to do this. You can't run the car with std ECU & 800cc injectors and you can't map your ECU until they are fitted if you intend on using them so they need to be done just before ECU is fitted. I don't see it being sensible to be doing this in the ECU Fitters car park.

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PostPosted: Thu Jan 30, 2014 6:07 pm 
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I'd like to confirm some of the new seals etc that I will need, this is what I have to date:

Image

The injectors are brand new and have 2 o-rings installed on each one. I also have 4 of the injector isolators shown in the photograph.

Below is the diagram from the EPC which shows a total of 5 seals for each injector:

Image

Now I am pretty sure those circled in green are the seals that I already have fitted to the injectors, according to ToyoDIY the part numbers are:

90301-14006 No1 O-Ring for Fuel Injector x4
90301-17007 No2 O-ring for Fuel Injector x4

The gold/orange seal ties back to the part number I have for the seals in my photograph above:

23291-88480 Insulator, No1 Injector Vibration x4

That leaves the seals marked in red and blue which appear to tie back to the same part number of which there are 8 on the car, 2 per injector:

23291‑75010 Insulator, No2 Injector Vibration x8

Can someone check my working please and confirm that what I am missing is the 8x 23291‑75010 Insulator, No2 Injector Vibration seals which are the ones marked by the red and blue.

Fortunately TCB list these and they are 0.79p +VAT

Cheers :)

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PostPosted: Thu Jan 30, 2014 6:16 pm 
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Diceman wrote:
Mike,
1) the injectors if new are prone to being "sticky" use a 12v car battery and 2 pieces of wire to check they are working OK before fitting and to give them an initial kick into life. Just very briefly touch the injector terminals with the wires to open & shut them (you will hear a faint click). If you remember correctly when we fitted mine at K&Ls I had a sticky injector or 4 as they had been sat on the shelf for a while.

2) why not get the ECU fitter to install them - IIRC most places will charge around £75 to do this. You can't run the car with std ECU & 800cc injectors and you can't map your ECU until they are fitted if you intend on using them so they need to be done just before ECU is fitted. I don't see it being sensible to be doing this in the ECU Fitters car park.


Hi JP,

Yes I do remember much confusion over your injectors when fitting them originally, I will be sure to 'liven' then up before putting them in.

On number 2 I have been deliberating this as you say they need to be installed just before the car is mapped. Potential solutions I came up with are:

1) Pay them to install the injectors - simplest.
2) Fit the injectors in the car park, not ideal, never done it before, risks if I can't get the work done in time.
3) Fit the injectors at home and then have the car trailered up, lots of cost, cheaper options not available mid week, its a real bugger loading up cars unpowered.
4) Fit the injectors and have them send me the ECU with a basemap suitable for 800's on it so I can drive gently to the tuners, far too many risks imo.

So I think I will just have the tuners install the injectors first thing when I get there.

Cheers :)

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PostPosted: Thu Jan 30, 2014 7:41 pm 
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If you have an AFR gauge fitted then it's not difficult to do a 'get me the tuners safely' map. We did this on Terrys G4 and ended up driving it up to Brum from Southampton services as his transporter was having injector problems.

I tweaked the timing on the installed base map to be a bit closer to the stock ignition map, and set the fuelling in about 10 miles of dual cabbageway and minor road. The link base map is a joke, but it did at least get the car started so i could tweak it.

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PostPosted: Thu Jan 30, 2014 7:42 pm 
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p.s. What ECU are you planning ? and which tuner ?

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PostPosted: Thu Jan 30, 2014 8:16 pm 
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Nibbles wrote:
p.s. What ECU are you planning ? and which tuner ?


Hi Chris,

Not finally decided yet but will have an update tomorrow.

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PostPosted: Thu Jan 30, 2014 10:35 pm 
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correct:-
St205 Injector Insulator (rubber O ring - 2 per injector) 23291-75010 £0.46
ST205 Injector Insulator 23291-88480 £3.94

http://gt4dc.co.uk/forum/viewtopic.php?f=2&t=2388

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PostPosted: Thu Jan 30, 2014 10:42 pm 
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Thanks :)

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PostPosted: Fri Jan 31, 2014 2:31 pm 
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Parts ordered today, thanks for the assistance.

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PostPosted: Sun Feb 09, 2014 5:39 pm 
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Hiya mike

Injectors I like to send away as had a few ones with quite some flow differences and even improved new ones so maybe worth doing even if just for piece of mind

Martin

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PostPosted: Sun Feb 09, 2014 6:17 pm 
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Hi Martin,

Thanks for the tip. I already had these new ones flow tested when they arrived :)

This showed that they actually flow 860cc rather than the 800cc advertised :)

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