davek9

I had 4 of 8 doing the same, they can be bench tested with a mightyvac see my 86.5 auto onion thread.

Mrmerlin

Dave chances are that the cleaning solution that was used to clean the injectors may have damaged all of them.
Maybe one of the non leakers starts leaking after a few heat cycles and the OP wont know that till there is smoke curling up from the sides of the hood.

NOTE since they were not leaking when they were sent off and now some of them are it would be prudent to scrap the lot of them and start with a fresh set of injectors.

This isnt an area where I would want to cut costs.
Neither should you or the OP, YMMV

davek9

Agreed, that's why I'm suggesting bench testing be for installing.

I bench tested all mine before installing and also pressured tested the installed Fuel Rail/Injectors at the Fuel Inlet line before sending any fuel through.

From now on thats the way I'm going to do it when they need to be serviced or removed. Sure beats fuel all over the engine compartment .

It's easy w/ a Mighty Vac tool.

Mrmerlin

Dave I would suggest new injectors not rebuilt if you have found any that have been leaking.
Just because a 30 yo injector passes your bench test after you found a few leaking should be a clue to you.

Ahhh Vell.
Like I said before this isnt an area where being cost conscious is a good idea,
I am surprised you would even suggest this, you have been here long enough to know better, atleast you have a fire extinguisher

Dadddio

Gonna get new ones.

Mrmerlin

^^^^^Great idea let us know how things work out

Hilton

You didn't say whether the kits you used are the complete Bosch kit with the correct o-rings, pintle caps and spacers in a separate bag per injector? (they can be ordered using the PET part number IIRC). If not the Bosch set, it might be worth getting some Bosch o-rings for the top first.

The top of the injector at that point has a minimum design tolerance of 7.7mm where the o-ring fits.

The Bosch o-ring size spec for the top is 7.52mm +/- 0.18mm (and interestingly, for the design III aka EV6 body, which has the same dimension at that point as earlier EV1 injectors, Bosch changed the o-ring spec to 7.52 +/- 0.13mm - guaranteeing its slightly smaller than the injector body).

If the o-rings you're using can be rotated freely or have slack where they fit, they're too large. WhIle they might seal ok, if they twist or are pinched slightly by the fuel rail where the injector seats, it could create a small gap. I now only buy Bosch o-rings for my injectors.

edit: Correct o-ring specs can be found in the Bosch schematics in this post here.

edit2: I just looked up the correct Bosch part numbers.. they are:

S4 top o-ring (and top/bottom both for S3): 1 280 210 752
S4 bottom o-ring: 1 280 210 765

John Speake (JDSporsche.com) can supply both - last time I looked into it the S4 bottom o-ring part was hard to find in the USA, but John was able to get them. Being small, international postage on o-rings probably won't be crippling either

Dadddio

Got the kit from Roger.
I was able to see small bubbles coming from the injectors.
Not gonna mess with them anymore.

Hilton

Ah - I missed the post where the bubbles are coming from the join lower on the injector body. Definitely replace

Dadddio

YESSSSS!!!!!!
Got her running....No leaks.
Thanks to 86_5Tiburon and his timely sale of used injectors.
Running a little rough.
I'm pretty sure the timing is off a bit.
First drive around the block.
Very satisfying.
Sounds great.
Thanks for all past and I'm sure future help.

Kevin in Atlanta

Wow, that was fast indeed. Glad it worked out!

Kevin in Atlanta

You want to try some injector cleaner. Let the car get down to almost empty, add the injector cleaner and drive it! That has worked for me in the past.

Dadddio

I will try that.
And thanks again.