Replace injectors K R500 - Bosch 0280155868

[anthonym]

back to ECU thread

  K

25.4 / 267  /  192  /  43.5  /  3

https://www.bosch-automotive-catalog.com/en/product-detail/-/product/0280155868

R500. Bosch injectors 0 280 155 868        LBS/Hr  25.4 - CC/Min 267  -   GRAMS 192  -  PSI 43.5  -  Bar  3 (begs the question how to measure fuel pressure)

This looks easy?

Disconnect loom connectors x 4

Undo two bolts holding a rail in place

Snip any blocking cable ties

(most cars not mine: remove retaining clip from each injector)

Pull rail away from injectors - which will fall out or not

Remove injectors

THEN

My car only : Install additional « square o-ring behind block end o-ring ( still trying to source these)

Insert injectors to body (?) reapply the rail, make sure everything seems snug on their O rings.

Rebolt rail in place

(most cars not mine: refit retaining clip to each injector)

Refit removed zip ties.

Reconnect connectors x 4

Start engine.

Check for fuel pressure before removal so essence doesn't go everywhere.

Work in an aired place because petrol vapour is highly flammable and expands to occupy a vast amount of space.

No smoking, naked lights or other sparks.

What else? 

Nothing is ever as easy as it seems: and so it has transpired.

I made this all up after a quick glance at the engine. 

I wonder if this is pertinent to my mapping matter here TPS Emerald adventure #161

ASSUMPTION: there are no adjustments whatever that can be made to the injectors themselves, so replace like with like to maintain the status quo. That then leaves the difference between brand new injectors and any compensations introduced for the older injectors when the ECU was mapped. 

Anthony

daft realisation: injectors are electrical components. I replaced my engine loom because of faulty electrical components (connectors in fact), tested all the sensors, never thought about these. Examining a new injector it strikes me they are just a sort of tap (now confirmed), so the fuel pressure will be crucial to how much fuel is injected when the "tap" is opened. Having only two connects presumably it is either open/on or closed/off.

"injector scaling"

Bosch injectors 0 280 155 868 technical data from http://www.gomog.com/allmorgan/InjectorRatesBosch.html

- 382cc/min = 261g/min = 35lb/hr @ 3bar
- Single cone spray
- Long body length
- Regular tip nozzle
- 12 ohm resistance
- Jetronic connector

My car is not quite unique in having “centre” o-rings very difficult to identify and find here:

 

 

This search engine includes CATERHAM models:

https://www.bosch-automotive-catalog.com/en/internet/ECAT-RS/vehicle-info/-/vehicle/equip/CTE/34/58e50rqs9bvqs3m6odvc7to3c1dp760e

[anthonym]

 Job done. 15 mins. Engine starts nicely.

[SM25T]

Any less toxic?

[anthonym]

Missing the centre O Ring, searching for supply. Situation dangerous without them because there is nothing to keep the injectors from coming loose. My car does not use the clips.

https://www.bosch-motorsport-shop.com.au/?rf=kw&kw=o+ring

https://www.mrinjectorparts.com/store/p282/Bosch_Fuel_Injector_Service_Kits_027.html

https://www.mrinjectorparts.com/store/p18/Bosch_Type_3_Fuel_Injector_Service_Kits_002.html

changing search to "injector seals"

changing search to "square cut 0 rings"

https://www.efisolutions.com.au/injector-o-ring-lower-seal-s13-180sx-r32-r33-r34-a This insulator pushes into the intake manifold and seals the injector to the intake manifold.

[rj]

I would sink these would do:

https://www.ebay.de/itm/Einspritzventil-Einspritzduse-Dichtungen-O-Ringe-Mercedes-W-124-E-220/332118275739?_trkparms=aid%3D555018%26algo%3DPL.SIM%26ao%3D1%26asc%3D20140117130753%26meid%3D805ac1a48ae8480095301cbc78828d5e%26pid%3D100005%26rk%3D1%26rkt%3D12%26sd%3D332133411121%26itm%3D332118275739&_trksid=p2047675.c100005.m1851

 

[aerobod - near CYYC]

It looks as though all Bosch 0280155/156 series injectors seem to be sold with the top and bottom ‘O’ rings only, I couldn’t find any with the mid seal installed. I would think it is best to call Titan as the original suppliers of the R500K throttle bodies and fuel rail suppliers or Minister as the engine builders, I’m assuming one or other of them sourced the mid seals. It may be possible to use a standard Viton ‘O’ ring seal instead of the tapered seal you currently have, you can find them online in mm or half mm increments in ID and OD.

[oilyhands]

The mid seals are not a standard fitment, normally the injectors are chipped to the rail to stabilise their position, That would make the mid seal redundant, I have only seen them fitted on one of the many RX00 TBs I have had here.

Oily

[anthonym]

I imagine the above may have become stretched over the years.

from James: (thanks)

With external compression over time, the cylindrical 'O' ring probably
started out at 14.5mm oD (the usual quoted diameter of 'O' rings for Bosch
injectors). I would say you need a 5mm x 2.5mm x 14.5mm OD Viton cylindrical
seal. linky

These (pictured above) are the ones off the old injectors. I will head down to the o - ring shop (Missilier) a bit later and see what they have.... they are now searching their own sources.

Clearly the clips are a backup solution if I have to, if this arrangement is so unusual and I could use these old ones, but I after nearly 20 years I think the rubber needs a rest.

Thanks for your various comments and searches, it helps.

edit to add: I don't know if it was my imagination but the engine sounded so very sweet when started... 

Update 13:00 (local ;-) ) they are searching..

Types of o ring

https://www.martins-rubber.co.uk/blog/an-o-ring-material-selection-guide/

anthony

 

[oilyhands]

The clips are fitted to just about every injector of that type that I have seen fitted , they are there to prevent the injector parting company with the fuel rail in extreme circumstances. If it were me I would go with the clips, much more secure.

Oily

[revilla]

Anthony, set of used clips will go in a bag for you tonight. Will try to get them posted tomorrow. PM me your postal address again (yes I know I've been there but I've been to bed since then).

[anthonym]

Duly noted. Andrew is donating some (thanks :-)  )

This made me wryly smile when considering the conditions my o-rings have been in for 19 years:

Over 40 million pieces are stocked in a high-tech warehouse that can guarantee the ideal storage conditions of O-rings and seals, protecting them from shifts in temperature, light exposure, gas and corrosive agents.

linky to said stock

https://www.o-rings.eu/disponibilita-magazzino.asp?txtDiametro=7%2C66&txtCorda=2%2C78&compound=&color=#ricerca-magazzino

 

[aerobod - near CYYC]

With external compression over time, the cylindrical 'O' ring probably started out at 14.5mm oD (the usual quoted diameter of 'O' rings for Bosch injectors). I would say you need a 5mm x 2.5mm x 14.5mm OD Viton cylindrical seal.

Something like this may compress enough to fit: https://www.dhgate.com/store/product/100pcs-universal-injector-viton-oring-high/428739940.html