Injector Post-mortem Diagnosis

[jonathan1173]

1997 D21 XE 5-speed 2wd.
As is common when doing a rebuild, I come across worn parts that are better replaced now than later. When reinstalling the fuel rail to the manifold, I decided now is a good time to re-ring the injectors. After pulling them from the fuel rail, I noticed one was much worse than the others. Prior to storing, truck was running rough, etc. I suspect a dead injector causing truck to only run on 3 cylinders
I've decided to replace all four before continuing assembly. Any idea what could have been the cause behind this?
http://i921.photobucket.com/albums/ad53 ... ectors.jpg
http://i921.photobucket.com/albums/ad53 ... 1554_1.jpg

[WDRacing]

Looks like the inside rusted out. She'll run great with a new set of injectors and fresh plugs.

WD

[whomadewho]

WDRacing is correct - Rust out! Jonathan1173. Really courious,how did you manage to remove the Phillips screws that hold the cap in place?? I have a miss fire in number 4 tried briefly to remove the screws,looks like It could turn into timing consuming project.

[whomadewho]

WDRacing is correct - Rust out! Jonathan1173. Really courious,how did you manage to remove the Phillips screws that hold the cap in place?? I have a miss fire in number 4 tried briefly to remove the screws,looks like It could turn into time consuming project.

[jonathan1173]

Thanks WDRacing. What causes rust out? Anything one can do to prevent in the future?

[jonathan1173]

WDRacing is correct - Rust out! Jonathan1173. Really courious,how did you manage to remove the Phillips screws that hold the cap in place?? I have a miss fire in number 4 tried briefly to remove the screws,looks like It could turn into time consuming project.

Whomadewho,
It has been quite time consuming, as I've had to tear down to the pistons and build up from there. Numerous delays to source/ save up for parts.
After the system is de-pressurized and fuel rail had been removed, I placed the rail on the bench. A good dose of PB Blaster, overnight soak, wiped dry, then used Vise-Grips held perpendicular to the screws. (Rail laying flat, visegrips straight up and down).
I used a pair of channel-lock pliers to close Vise-Grips onto the screw as tight as possible, then twisted grips using large screwdriver wedged in between the two handles of the grips.
Needless to say, I DID NOT re-use the screws. Home depot stocks machine bolts, M5 0.8x 20mm I think. Just take the old screws and match them up.
Found some re-man Beck-Arnleys on Rockauto for under $30 apiece, get 'em before they're gone.

[jonathan1173]

Replacement hex bolt size is M5 0.8 16mm
Replacement hex bolt size for fuel pressure regulator is M5 0.8 12mm

Home Depot SKU
887480013283 METRIC BOLT - Lock washers
887480013481 METRIC BOLT P/.08 5X10 ZINC HEX BOLT METRIC 5MM-.8X16MM ZINC
887480013382 METRIC BOLT P/.8 5X12 ZINC- 12mm

All can be had for about $5 which is well worth it, considering you won't have to lament over those POS phillips screws again!

[WDRacing]

From my what I've read fuel injectors don't play well with water...at all. Possible contamination could be from ethanol that has absorbed water. Hard to buy gas without some ethanol in it these days.

All it takes is for a small bit of corrosion to start and it spreads rapidly.