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1987 928S4 Fuel Rail Is Stuck (Removal Help)
I’m trying to get at my fuel injectors on an ‘87 928S4, but the fuel rail is stuck at the end by the firewall. Also, it looks like at least some of the injectors are lifting up with the fuel rail on the end that is free. I’m using the directions provided here: https://www.928motorsports.com/insta...eplacement.pdf It says to remove the two 10mm bolts that hold the fuel rail down, then wiggle it and pull it off. Shouldn’t I remove the clips from the top of the fuel injectors first? And if I do how do I reverse the process (not much room in there for big hands). Does anybody know how to address this problem? |
It can be a bear! Just put some spray lube on the o-rings at the intake and pull and wiggle. You can pull them as a unit on the rail or remove the clips and remove the rail from the top of the injectors. I have read that spark plug boot pliers work well to assist in removing injectors from the intake.
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Yes you can remove the clips from the top of the fuel injectors first.
Easier I think to remove the rail that way. This photo was taken from one of Dwayne's Garage procedure. https://cimg4.ibsrv.net/gimg/rennlis...865a27e81b.jpg https://rennlist.com/forums/928-foru...re-w-pics.html Forget the attached image bellow. |
When you finally pry off the fuel rail and usually when stuck this bad, the O rings and the pintle caps at the end of the injectors will stay in the manifold. You could try disconnecting the injectors from the rails and then try to remove them from the manifold but be prepared that they will come apart.
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Originally Posted by Imo000
(Post 14823965)
When you finally pry off the fuel rail and usually when stuck this bad, the O rings and the pintle caps at the end of the injectors will stay in the manifold. You could try disconnecting the injectors from the rails and then try to remove them from the manifold but be prepared that they will come apart.
I’m headed over to get this done right now. I really hope none of them break,I’ll shoot WD40 on the stuck ones before trying to get them out. I was hoping to get them cleaned and stay “original,” but if they can’t be saved I see 4 hole Bosch injectors on eBay at a great price, but I don’t know if they would be plug and play or if some tuning would be required. |
Nothing will break, it just feels odd the first time you do this.
If pintle caps fall into the head, so what. Theyre just nylon. Most will sit on a valve, and you can get em with a grabber tool or something..but if a valve is open, eh. Make sure to maybe blow air around the injectors to get any sand or other debris away, and also the injector harness wire clips will want to fall off when you unplugged them, make sure they arent able to fall in there either. |
Originally Posted by Speedtoys
(Post 14824039)
Nothing will break, it just feels odd the first time you do this.
If pintle caps fall into the head, so what. Theyre just nylon. Most will sit on a valve, and you can get em with a grabber tool or something..but if a valve is open, eh. Make sure to maybe blow air around the injectors to get any sand or other debris away, and also the injector harness wire clips will want to fall off when you unplugged them, make sure they arent able to fall in there either. Am I supposed to actually “pry” these rails/injectors up? |
Originally Posted by Marquis777
(Post 14824131)
I put some WD40 on the stuck injector and went to the other side, it’s rear injector is stuck too! Am I supposed to actually “pry” these rails/injectors up? Is there anything special about unplugging the connectors on the injectors? Please let me know. |
Originally Posted by Marquis777
(Post 14824159)
Yup, I used a pry bar with light pressure and it popped up. Yay! Is there anything special about unplugging the connectors on the injectors? Please let me know. |
Originally Posted by Imo000
(Post 14824203)
I used a prybar too with slight pressure. Use a dental pick to pull back the stainless steel U shaped wire that lock the injectors connectors.
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Originally Posted by Marquis777
(Post 14824210)
Oh, ok thank you! Also, did you rebuild your injectors or buy the 4 hole version? |
Originally Posted by Marquis777
(Post 14824320)
Well now I’ve got stuck fuel injectors, 😂. Did you have that problem too? Also, did you rebuild your injectors or buy the 4 hole version? If you are reading this thread and have a couple of injectors that won’t come out go to Amazon or 928 Specialists and grab a puller. Schley Products, Inc (SCH83400) Volkswagen, Porsche and Audi CIS Injectors Puller
$ 16 59 Free Shipping for Prime Members |
Bringing this back. Does the same procedure apply to an 86.5 ? has anyone come up with a slick system or any "new " tools or suggestions for removal? It seems prying straight up would be the ticket but I dont want to bust anything. I have the larger injectors from Roger ready to go in.
Thanks in advance JD |
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WD 40 isnt a great lubricant. Drop some light sewing machine oil around base of each and wiggle/ work the fuel rail for a minute or so. Then lightly pry with pry bar and small piece of wood.
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