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Old 08-16-2021, 01:44 PM   #1
jrhudson
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Direct injectors installation issues.

Hey im installing my direct injectors to my engine and with the injectors in the fuel rail. When i tried to installl the fuel rail with the injectors, there was alot of resistance. I pushed pretty hard on the fuel rail to try to get those injectors in but didnt work.

When i pulled out the injectors, the seals looked ruined now. How the heck do i install the DI without damaging the seals? Does it just drop right in or is there suppose to be alot of resistance?

Pics are of the the fuel rails and the gap between the threads and fuel rail.

Other one is pic of injector seal after attempting to install.

Any help would be greatly appreciated
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Old 08-16-2021, 01:44 PM   #2
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Injector seal before installation.
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Old 08-16-2021, 02:32 PM   #3
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I suspect the company who i got to do the injector cleaning and re seals didnt do it properly. 2 of my seals have torn

Fudge me. I spoke with the company and they said that in the service manual youre suppose to put the injector in the freezer to shrink the seals. But i dont see it in the service manual. Ugh. Well my build as stalled again
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Old 08-16-2021, 09:43 PM   #4
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It doesn't exactly slide right in, but the entire assembly tightens down smoothly.

Did you wipe off the injectors before you snapped the after pic? I imagine it would be pretty difficult to get these in dry. I think our service manual relies on leftover oil from the seal installation. Mazda actually specifies applying engine oil directly to the cylinder head hole.

Never seen anything about freezing these either.
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Old 08-17-2021, 01:59 AM   #5
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Originally Posted by itschris View Post
It doesn't exactly slide right in, but the entire assembly tightens down smoothly.

Did you wipe off the injectors before you snapped the after pic? I imagine it would be pretty difficult to get these in dry. I think our service manual relies on leftover oil from the seal installation. Mazda actually specifies applying engine oil directly to the cylinder head hole.

Never seen anything about freezing these either.
Yes i did clean them after i took the photos.

yea im sure the company i was speaking with was just trying to cover their asses. And they were aftermarket seals, which were slightly longer than the oem seals. I have the OEM seals on hand but no SST tool so im waiting for that in the mail.

it does make sense though for freezing it since the seals are so pliable.
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Old 08-17-2021, 12:00 PM   #6
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Quote:
Originally Posted by jrhudson View Post
I suspect the company who i got to do the injector cleaning and re seals didnt do it properly. 2 of my seals have torn

Fudge me. I spoke with the company and they said that in the service manual youre suppose to put the injector in the freezer to shrink the seals. But i dont see it in the service manual. Ugh. Well my build as stalled again
Damn if ive seen this earlier i mightve have told you to do the same.

I think i know what company youre talking about. Because when i had to do this, the same problem happened to me. I spoke with them about it and I was told the same thing, but I knew for sure it doesnt say shit about freezing them in the service manual. I had it out when i called them.


In the end i went with OEM seals since they are slightly shorter. Yea just so anyone else runs into this issue. Just use the OEM seals. They work and its meant to work there from factory.
6k miles built motor and everything is fine, so far.

TDLR; use oem seals. Freeze them if youre having trouble. But just stick with oem seals.

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Old 08-20-2021, 12:35 PM   #7
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Quote:
Originally Posted by jrhudson View Post
Hey im installing my direct injectors to my engine and with the injectors in the fuel rail. When i tried to installl the fuel rail with the injectors, there was alot of resistance. I pushed pretty hard on the fuel rail to try to get those injectors in but didnt work.

When i pulled out the injectors, the seals looked ruined now. How the heck do i install the DI without damaging the seals? Does it just drop right in or is there suppose to be alot of resistance?

Pics are of the the fuel rails and the gap between the threads and fuel rail.

Other one is pic of injector seal after attempting to install.

Any help would be greatly appreciated
Looks like you hulked the injector by quite a bit to flare the seal that much.

1. clean out the injector hole thoroughly

2. use a VERY light amount of lube. Bare minimum to make it slightly slippery

3. freeze the injector to shrink it. Cold stuff is smaller. You do this because you can't exactly heat up your engine block. Whoever told you to do this knows what they're doing.

4. get it done professionally if you don't know what level of force is normal.
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Old 09-12-2021, 01:07 PM   #8
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What did you do to install your injectors? Install instructions for GDI seem rather vague. Most make it seem that they should just slide in. I get mine back from cleaning and testing next week and would obviously like to avoid any mishaps. Did you follow @CSGMike's instructions? Thanks.
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Old 09-12-2021, 08:40 PM   #9
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What did you do to install your injectors? Install instructions for GDI seem rather vague. Most make it seem that they should just slide in. I get mine back from cleaning and testing next week and would obviously like to avoid any mishaps. Did you follow @CSGMike's instructions? Thanks.
You have to use a sst tool. Its gonna be expensive for a tool you’ll likely use once, hopefully. I bought the replica. Works great. For actually doing the job, just look on youtube. I believe it was a user on here that made the video. Just search direct injector brz or frs should be like the first video. Its not as hard as it seems but i suggest you buy more than 4 seals. I used 7 but had 12 ready to go. Call ahead for the dealerships to order them for you

The seals are surprisingly malleable and could be damaged easily. Just take your time and for sure FREEZE THEM.

https://www.freedomracing.com/09260-...t-st-s919.html


Found the user and link

https://www.ft86club.com/forums/show...ght=Fuel+seals

I followed this guide along with freezing them for a good while. Like 1-2 hours in the freezer.

Last edited by jrhudson; 09-12-2021 at 10:09 PM. Reason: Found user for seal installation guide
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Old 09-13-2021, 09:07 AM   #10
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Originally Posted by jrhudson View Post
You have to use a sst tool. Its gonna be expensive for a tool you’ll likely use once, hopefully. I bought the replica. Works great. For actually doing the job, just look on youtube. I believe it was a user on here that made the video. Just search direct injector brz or frs should be like the first video. Its not as hard as it seems but i suggest you buy more than 4 seals. I used 7 but had 12 ready to go. Call ahead for the dealerships to order them for you

The seals are surprisingly malleable and could be damaged easily. Just take your time and for sure FREEZE THEM.

https://www.freedomracing.com/09260-...t-st-s919.html


Found the user and link

https://www.ft86club.com/forums/show...ght=Fuel+seals

I followed this guide along with freezing them for a good while. Like 1-2 hours in the freezer.

Thanks. My seals should be on the injectors when I get them back. After freezing them and some lub, do they insert fairly easily?
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Old 09-13-2021, 11:35 PM   #11
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Thanks. My seals should be on the injectors when I get them back. After freezing them and some lub, do they insert fairly easily?
No, they still need a good amount of force. When mine eventually went in, i heard a little pop sound. like a potato launcher pop noise. sorry i suck at descriptions. good luck.
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Old 11-06-2021, 07:34 PM   #12
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When the seals are installed, the end in the up position usually gets mushroomed or tuliped on the end. If you try to install it this way, it slides too far up the injector resulting in the torn seal as you have above. Once the seal is on, you have to either use the proper tool to slide over it to re shrink it to be square on the bottom, or devise a tool to do the same. The seal will slide up the shaft some. That is how it seals. But when the seal is tuliped, it gets a head start and goes too far up the shaft and tears.
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