Possible 42.5 lbs injector installation issues and fixes - GM Forum - Buick, Cadillac, Chev, Olds, GMC & Pontiac chat


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Old 03-26-2008, 01:36 AM   #1
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Default Possible 42.5 lbs injector installation issues and fixes

Well I decided I would start a new topic regarding this problem.

Heres what happend. I purchased new injectors (Lucas 42.5 lbs) from INTENSE.
Injectors fit well and seat as they should without the stock fuel rail attached.

NOTE* This is not the correct way to install injectors, stock or otherwise. Correct method is to have the injectors in the rail with the metal retainers installed so they won't move around on you.

Now, all this being said, you might ask, well whats the issue? The injectors will not seat at all with the rail attached, no matter how you try, it will not happen. I discoverd the reason why not looking at my car, but looking at Slayer636'* 1999 Buick Regal Supercharged. He has the OEM new style Lower intake manifold gaskets installed. These gaskets are notched out more than enough to allow injector installation and proper back and fourth movement to allow them to seat properly. I have an aftermarket set installed from a few years ago, brand name is fourthcoming when I find my recipt.
They do NOT have these notches and over hang a little bit...not TOO much, however, just enough to allow the new injectors not to move.
Why did the stockers install a few years back no problems but not the Lucas injectors?
Heres why:

Lucas injector is physically much larger.
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Theres the overhang I was speaking of earlier.
The Fix? You could purchase a new OEM set from the dealer or INTENSE, but I am not about to do that again this year. So with my standard "high speed cutting bit" installed on my flexible dremel tool attachment, I CAREFULLY made the overhang dissapear. I paid close attention NOT to get any waste material in the injector bosses.
I made a plug out of thick paper towell, stuffed it into the hole, then made sure the area was clean after cutting and used a pair of needle nose to remove.
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The first hole all cleaned up.
How did I keep crap from getting into the other holes while working beside them? I have an old set of old stock injectors from another car.
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Holes are plugged now. You could easily make 6 paper towell plugs however if you need to.

CAUTION: If you have to do this to install the injectors make damn sure you don't nick the area were the Oring on the base of the injector must seat into the hole in the head. This will cause a leak, and could easily cost you the head itself.

For the Series 1 guys, our injectors on the Series 2 install into the heads themselves, not the Lower intake manifold.

I am making this a sticky as I think someone else might find this usefull.
With any major mod, I reccommend all new gaskets and such, to prevent any cutting the OEM gaskets must be used. I am not sure on the Felpros, however a quick inspection of them will let you know pretty easily.
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Old 03-26-2008, 03:24 AM   #2
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Why has no one else had this problem

Good fix if it works for you.
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Old 03-26-2008, 09:07 AM   #3
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It'* all in the brand of LIM gaskets. Matt doesn't recall what these were. Fel-Pro and OEM gaskets don't have the problem.

It was a good find. The advantage of having Slayer636'* Regal handy is what showed the difference and got him looking this direction.
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Old 03-26-2008, 09:38 AM   #4
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glad you got it figured out Matt

I can't believe your engine is that dirty! I would have never guessed....
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Old 03-26-2008, 10:46 AM   #5
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I'll figure out the brand today at work.
And, the engine hasnt been cleaned since...August 2007..haha..its due for a good 14 cans of degreaser. Ill have another post on that soon
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Old 03-26-2008, 01:05 PM   #6
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Good job Matt and glad to hear you got it all sorted out
Hope the weather gods are with you soon so you can that engine detailed, I'm about a month away
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