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Fuel Injector Seal Replacement 900 1994

posted by  Imken on  Sat Apr 11 03:37 CST 2009
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last visit: Fri Aug 12 11:03 CST 2011
[RELATED]

A little history before the questions:

For the past 3 winters I have had problems starting my 1994 940 in sub-freezing weather after returning home the night before. If I would wait a couple of hours after returning home and start the car but not let it reach operating temperture, it would start more easily on cold mornings. I have more recently had difficulty in hot weather after the car sat a while after a period of driving. After considering and testing a number of options, I concluded that the problem was fuel delivery-related and associated with failure to keep pressure in the fuel rail. The fuel pressure regulator had been replaced and pressure was acceptable, so I surmised it was the fuel pump check valve. Replacing that did not help (nor did the old check valve appear to be working improperly). I had also been smelling gasoline more frequently and finally noted that, after stopping, there was gas bubbling out around the point where the front injector enters the intake manifold. That would explain the loss of pressure in the fuel rail and likely generation of vapor in the delivery system as the rail heated after driving.

The questions relate to the removal of the fuel rail and problem injector. The FAQs are good but I would like a little more detail.

* First, I assume the leak I am observing is seal/O-ring related, right? The car runs great once started so I assume the injector is not the issue.
* It appears the one problem injector cannot be removed without removing the fuel rail, right? If that is true, then it would appear that the fuel rail must be removed from all 4 injectors.
* Is it best to remove the fuel rail from all 4 injectors to then remove the one injector for seal replacement, or is it better to remove all 4 injectors, lifting them away as a unit? (I'm concerned with contamination entering the other injectors during this process.)
* Would it be advisable to replace the seals on all 4 injectors if I am going to deal with the one with a leak? Maybe this would be required anyway if one or more seals is going to be broken on the other injectors, either at the fuel rail or intake manifold.
* Is there a good on-line step-by-step on replacing injector seals?

Thanks in advance for any help the Brickboard experts can provide.
Ron






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