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Old 16th April 2021, 19:24
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Default Fuel Injector Rebuild and Oil Filter Housing Plug, coolant tank and heater

Numerous little updates on the Sportster:

In 2005 when we build the car we had the fuel injectors out, added new o-rings and gave them run in an ultrasonic cleaner. They are now 33 years old and are overdue for a refresh. Found this company here in the UK who supply rebuild kits: https://mrinjectoruk.co.uk/ I send them an email before ordering and they advise BMW kit 10 was suitable for the 0 280 150 715 injectors. Arrived next day.



Rocker cover off for access, took the wiring harness off, loosed the 4 bolts holding the fuel rail on and pulled the injectors up and out. Had to remove the clips from the top of the injectors which hold them to fuel rail and I was able to get them out one at a time.





Condition as removed, pretty dirty. The o-rings are still in reasonable shape as they have been changed before.



The filters on the the other hand were dark and old looking. Getting the filters out took some careful manoeuvring with a screw driver and a pick.



While the cap, o-rings, spacer and filters were out dropped them into the ultrasonic cleaner



After all 6 injectors it was starting to look a bit disgusting



Shiny new parts!



Pushed in a the new filter and added a new o-ring:



Installed the new spacer, o-ring and cap on the other end.



Repeat 6 times for a full set!



Installation is reverse of removal, put all the injectors into the fuel rail first and add the retaining clips. Then carefully line up with the intake manifold and push into position. Reattach the fuel rail with the 4 bolts and reassemble the rocker cover and crank vent tube.



Took it for a good drive today, seems to run smoother and idle better, so Id call the a success! This job is not too bad to DIY, helps if you have an ultrasonic cleaner.

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The M20 engine leaks oil, this is one of the places it started leaking from recently. The housing which the oil filter connects to and the oil cooler pipes has a plug. This plug has an o-ring which has gone solid and started leaking. BMW Part number 11429059338 comes with a new plug and o-ring.



Some shouting and swearing to get the retainer clip out nothing to grab on to so screw driver in the divet on the left.



Quite a bit of oil comes out here when its unplugged.



This is the content under the plug, shown with new plug and o-ring.





Cleaned up the old parts to go back in.



Getting this thing back in was not the easiest job. Ended up using a clamp to force it into place and put the retaining clip in. Used screw driver in the cap to move it to the correct angle and location before removing the clamp.

This job took a suprisingly long time to do as it was quite fiddly.

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Purchased a new coolant expansion / header tank to replace the original 1988 part from the donor car. For the first time since building the car you can see the coolant level! Should have replaced this years ago, but it's not the cheapest part to get new. The nice thing is you can still get new original ones. They were use on the E30 and on the Z3.

Added a new blank cap to replace the level sensor cap with a fresh o-ring as well.

Needed little bit of modification for the lower mount a hole drill into it.





The old one is almost solid, the lower hose connection was coming to bits too, the metal insert on its way out the end.





Looks a lot nicer with the new tank.





You can really see the opacity difference.





Nice clear fill level:





Engine bay looks much cleaner now.

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