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[Tweek]

So, does anyone with good knowledge know if it'd be safe to run my Nissan injectors without the pintle caps? The reason I ask is because the thick Zetec lower O-ring becomes crushed and doesn't seal at all. Without the cap the seal should be able to do its job?

I understand there may be issues further down the line with fuel residue stuck to them or something but how long does this take to occur etc?

Photo from another thread but you can see the difference in seal size. I need the thicker Zetec Ford seal but there's not enough vertical space for it to fit and seal properly:


If you hear anyone say Jap injectors are a straight swap bar seals and plugs... it's all lies

[frst toady]

I no it would be a bit of agro
but surely you could get it machined out that little bit extra?

[MK4 Rick]

I was told for more fuel you could cut the ends off.

[Tweek]

The caps on these don't do anything for fuel output or spray pattern, the caps don't even touch the spray really lol. I'm not entirely sure what that old "shaving the caps down" means

[andymac]

Following up from FB chat, I see what you mean now about the size difference. I'd also guess the cap is supposed to stop the ring getting stuck in the manifold - I can't really see there being a problem removing them if they contribute nothing to the fuel spray patter.

EDIT: Also, not sure about the dimensions, but looks like there might be enough meat in there to get a .5mm larger ring (on the cross section) on the jap injector between the cap and seat ? That'd give you 1mm overall increase in OD - would that be enough to seal?

[Tweek]

Other way Andy

The OEM Ford ones are 3.52mm CS, the recess in the jap injectors is only 3.3mm. Dropping to a 3.0mm CS seal may well cure it but at a risk of the outer diameter being too small. Worth a gamble. If that doesn't work, pull the caps off .

[andymac]

Or pull off, shave off .5mm on the top side (the flange side) and refit ?

And when I say shave off, I mean "stroke gently across some 800 grit wet / dry then rinse off in oil or petrol"

As an aside, I wonder if the caps are available separately (and in different sizes).

Good luck mate, I feel your pain.