Need Tips For Fuel Injector Swap

Can it be done with the engine in? Looks like there's enough room but I don't want to start something I can't finish in a day.

Like this: https://rennlist.com/forums/996-foru...at-my-car.html Start to finish was about 3 hours, but split over multiple days for me. My children are very needy and want to see me on a daily basis.

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Awesome, I new I read a thread but could not remember the details. Chock that up to old age or a lot of partying during my youth! Did you work from the top or side?

Engine is lowered to the bottom of the MM, but I can't get my hand up and in. I can see a way to pop of the wires but not sure I could get them back on. Maybe if I remove the muffler mount?

Did you remove the airbox? On bank 1 you can remove the hose to the SAI pump and the coolant tank.

SAI is off and out. My fore arms stop at the coolant tank.

It is tight in there, no doubt. I am only 180 lbs and I managed. I also managed to ruin a shirt and several sets of rubber gloves. Maybe try bank 2 first? Sounds like you need to find some child labour.

Keep us posted Bill, the injectors are on my short list of things to do next. I keep waffling on doing it myself or paying my Indy, but I hate paying for labor!

I'm about to take this on too. Replacement injectors arrived today.

Has anyone installed the 996.2 injectors #996-606-122-00, Bosch # 0 280 156 053 in their 996.1 car? They look a little different physically, but I understand they will work if the slot for the retainer clip is opened up slightly. There is a thread here somewhere and this is talked about and Jake Raby confirms it. My engine is just north of 12k miles on an FSI 3.6 Street Performer rebuild. Since the build I've replaced O2s, coil packs, cats, plugs, and maf meter. I have had the injectors for a while, but have not been able to install them yet. I hope to get them swapped out this spring.

I caved in and bailed out for now.

At a certain point would you consider just ditching the mounts and dropping the motor down even further? You've done it, what, 10 times already?

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That's what I did but it's not enough. I needed my car today so I'll revisit this again later when I do my trans mount..

[QUOTE=essjayarr;16338646]Has anyone installed the 996.2 injectors #996-606-122-00, Bosch # 0 280 156 053 in their 996.1 car? They look a little different physically, but I understand they will work if the slot for the retainer clip is opened up slightly. There is a thread here somewhere and this is talked about and Jake Raby confirms it. My engine is just north of 12k miles on an FSI 3.6 Street Performer rebuild. Since the build I've replaced O2s, coil packs, cats, plugs, and maf meter. I have had the injectors for a while, but have not been able to install them yet. I hope to get them swapped out this spring.[/QOTE] This might be a moot point, but at only $73.00 each I purchased my 120-01 injectors from Sonnen Porsche. Perfect fit and came with O- rings installed. The install is fiddley enough without having to rework the clips IMHO. A couple things to be aware of, all these you guys have probably thought of: disconnect battery, have a fire extinguisher on hand and be prepared to lose all the unpressurized fuel from the fuel rails when pulling out first injector. One hint is to lower engine an inch & a half, remove SAI,.unclip wiring harness and get as much slack in wiring to pull fuel rail and injectors out as a unit. On bank two I had to remove coil pack wiring on cyl 6 to gain enough slack to work.

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[QUOTE=jumpy chunky;16339865] You can run some fuel out of the rails by removing the fuse to the fuel pump and briefly starting it. And having small hands with thin forearms helps...I never thought my hands where big until I tried this yesterday, the forearms, I knew about.

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[QUOTE=jumpy chunky;16339865] It seems the 996.1 injectors have come down on price quite a bit. There was a period when a new set couldn't be had under a grand and rebuilt was the other option. I've had my 996.2 version sitting on the shelf for a year by now. I probably would have bought the $76 new Porsche ones if they were available. So even right now, the difference is about $260 per set less for the 996.2 versions. There is no alteration of the retaining clip, but only a 5 minute each injector to widen the slot slightly. I think I got my 996.2 versions from Warehouse33 for about $36 each.

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[QUOTE=808Bill;16339888] Yeah, that's what Pelican parts said in they're tech article. So I did and didn't get rid of fuel just pressure. Or maybe my letting car sit for a week helped with pressure.

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[QUOTE=essjayarr;16339910] I think you will be the first to fit the 996.2 injectors to an earlier fuel rail. Hopefully the injectors are the same dimensions and connection point the same. I would guess there are two ways to make clips work. Wittle a little plastic away or possibly purchase the later style clips. Maybe you can post your findings when you have swapped out the injectors.

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[QUOTE=jumpy chunky;16348128] I won't be the first to do this. I had read about it here a while back. Jake Raby touched on having done this and mentioned doing a DIY video on it. During the back and forth emails while breaking my engine in, I asked if Jake had done a video on the modification. Here is the email from Flat6Innovations. Maybe Jake will chime in on the subject, ​​​​​​ Steve On May 14, 2019, at 8:22 PM, Raby Engine Development wrote:We have been tied up with the spring rush and have not done any videos. All you need is a hacksaw blade to make the groove a little deeper around the circumference of the injector body.. You�ll figure it out :-) On Tue, May 14, 2019 at 4:30 PM Stephen Rose < [email removed] > wrote:Hi Jud or Jake, I'm looking for some info. I saw some posts from Jake on therennlist about a short video for the modification to the Mkll fuel injector to use in my '99. I can't seem to find it. Did Jake ever find time to make it? I'm confident I could figure it out if I had both injectors in front of me. I just want to know as much as possible before ordering a set.

Looks like you received an email from Jake. I was not privey to that info. Seems as though that's all the info available for that modification,but others may chime in.

As others have said try right side first as it�s easier and you get to know what you�re dealing with. The main thing is to get the wiring harness out of the way, once that is done the rail can be lifted right up. Took me about 3 hours a side. I didn�t drop the engine so either I have sticks for forearms or the 997 has way more space. Definitely worth the work though. I did remove a silencer to get to the back injector but it probably wasn�t necessary. It all seems impossible but somehow you find a way. Still a better diy than the water pump.

The following is from the thread I read previously. It is from January 2019. 1-25-2019, 02:45 PM # 19 Flat6 Innovations Basic Sponsor Rennlist Site Sponsor Flat6 Innovations's Avatar Join Date: Nov 2010 Location: Cleveland Georgia Posts: 5,599 Likes: 0 Received 234 Likes on 142 Posts DefaultQuote: Originally Posted by Batteaux View Post To add to Jake's point about replacing tired injectors as preventative maintenance, I have decided to replace the injectors on my 3.6 FSI engine, which was a 3.4L originally. I think that something that scares off a lot of MK1 owners from replacing injectors is how expensive the specific 3.4L injectors are.....somewhere around $1.5K to $1.8K for a set. This leads one to look for alternatives to replacing (i.e cleaning, refurbishment etc). However the MK2 (3.6L) injectors can be had new for less than $40 each and it is my understanding that they will work on the 3.4L engine with a minor mod to them. Jake tells me they will be fine on my 3.6 FSI engine so I am going to put on new as they are relatively affordable (although the labour is the same) and will give great peace of mind! I am looking at this as preventative maintenance just like water pump, AOS etc. Glad to see that you are doing these injectors. Back when your engine was built we were only having the injectors professionally cleaned during an engine build. We had yet to connect these dots concerning injectors, and of course, the injectors were 7 years newer at that time as well. Concerning the injector mods, basically the groove that holds the retention clip is not deep enough in the replacement injectors to use the earlier rail/ retention clips. This groove can be made slightly deeper, and wider (when necessary) to accept the earlier clip. I plan a Rennvision video for this as soon as we get the chance. __________________ Jake Raby - Flat 6 Innovations Inventor of the IMS Solution: US Patents 8,992,089, 9,416,697 & 9,909,469 Inventor of the Single Row Pro IMS Retrofit, and Faultless Tool, with method of installation: US Patent 9,687,974 Inventor of the Faultless M9X/9a1 Piston/ circlip tool, with method of installation US Patent 10,267,419

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[QUOTE=essjayarr;16348420] Jake layed it out above, looks self explanatory to me. My issue may be the order that I assembled the wiring and fuel rail originally when I put the motor in. Thus making it a bit more challenging to do the first bank. I prefer to deal with the hardest side first and finish with the easy side last... I need to change my AOS again and do my tranny mount so I'll drop the motor and do it all at the same time.

The 2nd gen injectors have a better spray pattern too !