8 x Mazda BP o-rings (fuel rail side)
Flat head screwdriver
Router + grinding disc, optional sandpaper belt, polishing stone
Some Ford Crown Victorias ran such large capacity injectors to accommodate alternative fuels, commonly CNG (compressed natural gas). The injectors are made by Bosch and are identified by a black body with a baby blue, grey, white, or burgundy top. These injectors were also available in most Ford trucks. Remanufactured and rebranded units use all sorts of colors, some (like RC Eng) use their own body shell to try to further differentiate themselves. The injectors we're looking for were offered in CNG configured models from 1996 and up, and were also available on the E-250 & E-350 Econoline, some F-150 & F-250s, and other commercial Ford vehicles. I picked some up from Pick n Pull for less than a crisp $20 and bought a hot dog with the change.
: the orange units used in these pics were some extras I pulled from PaP to experiment on. Other than color and flow capacity, they are the same.
Alright, first let's compare our subject injector to a stock 323GTR injector (on right).
The mods performed are simple. The O-ring that fits into the fuel rail on the Ford-fitted Bosch units is too large, and we need to grind some plastic off to ensure enough of the injector fits in the fuel rail. Take off the O-ring using the screw driver as needed.
I started shaving off material on the top injector.
Next, use the cutting disc and/or sandpaper belt to grind down the plastic, up to the second groove. You want to shave it so that it's slightly slimmer than the Mazda BP o-rings we will later fit. Don't go too small, this part of the injector helps keep it stable inside the fuel rail. Shaving too much material will allow it to wiggle and potentially break the seal holding back ~50psi of fuel. Be careful not to puncture the metal, this may also lead to an engine bay fire.
Bosch units using EV1 injector harness connector
Next, use the polishing stone to round-off any bulges, sharp edges, or stray pieces of plastic that can dislodge into the fuel rail or interfere with the seal of the o-rings. Once it's smoothed and debarbed, slip on two Mazda BP o-rings in place of the old one.
Test-fit the injector in your fuel rail. Compare it to a stock unit to make sure they both completely fit the fuel rail. Check for injector play, they should be snug like the stock units. If they aren't, you shaved too much plastic away.
Upgraded Vishnu fuel rail, modified Bosche 1680cc, RC Engineering 550cc, stock 323GT-R 460cc
RC Engineering 550cc, modified Bosche 1680cc, stock 323GT-R 460cc (missing o-ring)
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