EFI Fuel Injectors

[kwilford]

Could anyone on this list tell me if these are the correct fuel injectors for the ’75 Opel Ascona with the Bosch EFI? Thanks!

[GTJIM]

Hi Keith,

Found my 1978 copy of the Illustration Catalog Opel and GT Models Thru 1975

Looked up Fuel System 1975 Model 50 and there is the injector: #36 Injector, Fuel Parts Group 817-------

Went to the Parts Book and foud that it only covers to 1974 Models so no fuel injection section *!!*

I think I do have the 1978 Parts Book so will search for it.
Till then maybe someone will be able to find a parts book with Parts Group 817--- in it. That's where the part number is.

[GTJIM]

Did a search on the Web "Bosch fuel injectors 0 280 150 105" and came up with all sorts of interesting stuff.

They are 1975 Manta injectors and also OEM for Rover Vitesse; Alfa 2.5L & 3.0L; Jaguar XJS; Porche; Renault & Triumph so I guess they are still available new.

Try www.boschusa.com also try a search for "0 280 150 105" on this buliten board www.opelgt.com

[kwilford]

I was doing a bit of restoration on my '75 SportWagon's fuel injection system this week, and I thought I would share some of my findings.

This car has the factory L-Jetronic EFI found on all '75 Opels imported into North America. I was told that it worked very well by the car's previous owner (Kat McCoy) when she drove it last year, but it was probably just in comparison to the numerous other faults that this car (a salvage rescue) had. And the Solex she had on her GT! I have discussed some of what I have found in other threads, but so far the biggest problems have been related to the very badly worn engine. I should be careful what I say, since I haven't really gotten into much of the rest of the car yet. I know the battery box needs replacing (I have a test repair kit from Charles Goin, but that will have to wait until spring). I have gone through the transmission, and bought a new clutch set and re-faced the flywheel. I know the steering rack needs new boots, which I have, and I have a spare rack and new ball joints and tie rod ends. But the wiring is still a MESS (!!). I know that as I dig more, I will find more. And so it goes...

Since the engine is due to be returned from the machine shop next month (new head, decked, with reconditioned valves, hardened valve inserts and brass valve guides; decked, bored and line-bored block; new cam; new lifters; new over-size forged high compression pistons; ground crank; all new bearings; new re-conditioned rods; new timing chain and tensioners; everything balanced; etc, etc, etc ad nauseum...), I thought I would get the fuel injection system in shape before the engine came back.

The first thing was to strip the FI system down and clean it. The AFM is still in the car, under a cover outside in the BLOODY cold weather, so it will wait until warmer days. Maybe when the GT heads off to the paint shop. The thing to do now was to get after the engine-mounted parts. Because it was on an engine that was quite worn-out, it was badly fouled due to oil coming through the EGR and PCV systems. The inside of the manifold was CAKED with carbon and oil, which resisted a couple hours of cleaning in my solvent bath. So, I have sent the intake manifold out to get hot tanked and bead blasted.

But there were also a lot of worn parts, most notably the linkage; the linkage roller bushing is worn out, as is the shaft bushing. I will see if I can get proper roller bearings to replace the delrin bushings. Interestingly, in almost every place a spring was mounted, the hole in the brackets are almost (or even entirely!) worn through. So I had to weld up every bracket and re-drill the holes. (I also lost one of the two throttle springs, so if anyone has a spare...).

And one of the bakelite fuel injector mounting bases had a stripped thread (the bolt that holds the injectors in place). So I installed Heli-coils in both plates. Much better than threads in bakelite (which is like a low-tech hard plastic). I will need new O-ring kits, but I see OGTS has them listed (and I believe that they are very common, since all Bosch MPI injectors of this type uses the same O-rings)

Most of the linkage had been Cadmium plated at one time, but it was all pretty much corroded away. So I wire brushed the rust away and painted it all with high-temp flat-black engine paint. Not as nice as powder coating, POR-15 or chrome, but it looks quite serviceable.

Next on my list is to find some rebuilt or new injectors. I did some interesting web surfing tonight (which led me back to this thread) so I will share that info in a later post.

Here are some photos, and more will come as the repairs continue:

[kwilford]

Oh, and while I am at it, here is a bit of a spreadsheet I have compiled about the Bosch L-Jetronic EFI Injectors and such. HTH

[Gary]

Keith - Don't forget to check the throttle body bushings for wear.
http://www.opelgt.com/forums/factory-fuel-injection/5013-throttle-body-repair.html

[tekenaar]

Originally Posted by Keith Wilford . . . hardened valve inserts and brass valve guides . . .

They use brass valve guides up there, Keith? Learn something new every day . . .

[kwilford]

Originally Posted by Gary Throttle Body Repair -------------------------------------------------------------------------------- Had a problem with the Wagon's engine running lean. Sprayed some carb cleaner around the throttle plate linkage and the car stalled. Checked a little further and noticed some side play in the shaft. I picked up a spare TB that was pretty corroded but had no play. Took it apart and found there was a pressed in bushing on each side of the throttle body. Using a punch from a hole transfer set, I pushed the bushing out. Did the same to the worn TB and swapped out the bushings. Vacuum leak fixed. The bushing was worn down ~.008 on one side. I'll post the bushing part number and dimensions tomorrow. (actually later today)

Thanks Gary, I looked at the throttle body, but the shaft seemed reasonably tight. But maybe I'll pull it apart and have a better look. Do you know what the allowable clearance is? Hey, can you post the bushing part number and dimensions? I know you used the old TB bushing, but do you know if Bosch or even jobber bushings are available off the shelf? Were both sides the same dimensions? I was going to take my shaft roller down to a local bearing supply store, so perhaps I will take the TB bushings down as well

While I am asking, did you have the same wear on the roller? On mine, the inner delrin sleeve was worn out, making the roller a bit wobbly. And the spherical delrin bushing on the end of the shaft seems a bit worn as well. Any suggestions as to what to use to replace that?

Thanks for the suggestions. Speaking of which, I am going to post a suggestion regarding having a separate forum for Factory EFI. See you on that forum...

[kwilford]

Originally Posted by tekenaar They use brass valve guides up there, Keith? Learn something new every day . . .

So, that would be "BRONZE" valve guides? Thanks for the "correction" Otto

[Opel1_9]

GTJIM, your "817" number s/b good.
The 1975 injector I have here has the following printed on the box;
On Line #1: 817 404
Line# 2: 08 983 637
Line# 3: GR.03.270

Hope this helps,
Ron

[Sportwagon75]

Originally Posted by kwilford (and I believe that they are very common, since all Bosch MPI injectors of this type uses the same O-rings)

Keith - I have part numbers from Python Injection and Standard for the injector seal kits. I'll post them for you. The Python kit comes with the plastic tips for the injectors and the tiny little filter screen on the inlet side of each injector.

[GTJIM]

This was listed at the top of the page in the Google Ads - they ARE worth a look from time to time!

http://store.yahoo.com/dpstore/fuel-...pel-manta.html

PS: Thanks Opel1 9

[azopelnut]

Hello Keith
What is the chance of you doing a pictoral how to like Rally Bob's "How to do a Big Valve head" or Opeldean's carb rebuild DVD??

[kwilford]

Originally Posted by azopelnut Hello Keith What is the chance of you doing a pictoral how to like Rally Bob's "How to do a Big Valve head" or Opeldean's carb rebuild DVD??

Paul,
Do you mean a "How to rebuild a Factory EFI" article? Well, the photos above were all that I took, and I have now re-assembled it. I was able to use parts from another EFI set to repair the worn pieces. I did install HeliCoils in the injector plates (probably should be done to EVERY injector plate!). I have bought NOS injectors over eBay, so I won't be going to the trouble of re-building my old injectors (unless I get bored some day, as I have probably 10 old injectors). So there isn't much left to document at this point.

[Sportwagon75]

Keith - Sorry for the delay. Injector seal kits are available from Standard, Python and Borg-Warner:

Standard part # - SK3
Borg-Warner part # - 274031
Python Injection # - 200-120

As noted, the Python kit is the most complete kit for the money. It has a number of parts not included in the Standard and B/G kits which only include the primary injector seal rubber and the rubber retainer ring. By the way...I noticed from your photos that you've disassembled the T/B for cleaning. Do you know of a source for all the other gaskets in the throttle body and the plastic injector plates, etc. Does OGTS have these F/I gaskets? I have several gasket head sets that are "supposed" to include the 75 model year but never seem to have all the F/I specific gaskets.

[Paul]

Scott,

When I disassembled, cleaned and repaired my old system, I bought new or was it good used injector mounting plates and gaskets from OGTS. The throttle body gasket I made from gasket stock.

[kwilford]

Originally Posted by Sportwagon75 By the way...I noticed from your photos that you've disassembled the T/B for cleaning. Do you know of a source for all the other gaskets in the throttle body and the plastic injector plates, etc. Does OGTS have these F/I gaskets? I have several gasket head sets that are "supposed" to include the 75 model year but never seem to have all the F/I specific gaskets.

Thanks Scott. I made my own gaskets for the injector plates, using the olds ones as a template. The throttle body gaskets were still in good shape, so I re-used them

[Sportwagon75]

So...does this mean there are no sources for all the F/I specific gaskets? Do we have to go to Germany for these things?? I guess I should just call OGTS to find out.

[David McCollam]

Scott,

Got some from OGTS a month or so ago.

Dave