I am going to replace my Pulsation Dampner on my 89 vert . I have bought the PD , but can you tell me what other gaskets , o-rings , clamps etc. I will need to have to put back the UIM, VDI etc. back together ?

Also , no special tools needed ?

Thanks

 

i'm pretty sure the PD is attached to the fuel rail and is non-removable on s5's.

 

Yes the S5 PD is a whole fuel rail integrated unit.

You will need a lower-to-upper intake manifold gasket. Since you will be removing the fuel injectors from the fuel rail, you will need new o-rings for the fuel injectors (get 4, 2 for the primaries, 2 for the secondaries while your at it). A few hose clamps for the fuel lines (8 in total i believe), you might as well buy about 6 feet of fuel injection hose to replace the old hoses coming off the fuel filter and going into the hard return lines, and the lines going to the pressure regulator rail and PD rail.

That's basically all you will need, I don't think I forgot anything on there.

Then of course you can replace all the old nasty vacuum lines under there. That's optional but highly recommended. Make sure to clean off that old lower-to-upper intake manifold gasket good. There is also an o-ring on the TB, but usually you can get away with it, it's up to you if you want to replace it.

Mazdatrix.com has everything I listed here, besides the fuel lines and hose clamps i believe.

As far as special tools, only thing you will possibly need is a torque wrench to properly torque the manifold back on, you don't want to strip the threads on the manifold or crack them like I have seen numerous times on here. Thats all you will need though. Unbolt the upper manifold where it meets the lower, i believe its only 5 bolts, don't worry about unbolting the middle section and top section of the upper manifold, it all comes out in one piece. It's really easier than it looks.

 

Bugger^^ he got it before me

 

Thanks . Thats a big help . I bought the new S5 fuel rail with PD last year but never put it in . Smelled some fuel and saw a couple drips last week under the manifold and need to get it done . I don't need vac lines , they are all new from a rebuild 2 years ago

 

Does the shopping list change at all if you're replacing the S4 NA pulsation damper? Mine's not leaking and the car only has 41,000 miles, but I plan on replacing it soon just to be safe.

 

No, same thing, you will just get the PD itself, not the whole fuel rail.

 

Actually, I already bought the PD last year to have on hand in case I developed a sudden leak there. I've been putting off the project because ideally I'd like to also replace my OMP lines and do the full vacuum line replacement at the same time. Might send the injectors out for cleaning then too. Could be a good project for winter when the car isn't being driven as much.

I could swear I remember something about some brass or copper washers on the fuel rail or something like that which should also be replaced. Maybe I'm just thinking of the injector o-rings.

 

A copper crush washer is used to seal the PD against the rail body. Take a look here for pictures: http://www.mazdatrix.com/c-pulsation.htm. You can probably get away with re-useing one, but there's no reason to chance it.

 

Thanks; I never noticed that page on the Mazdatrix site. Looks like there are two copper crush washers. One "at the damper" and one "at the fuel rail." For the $5, I'll pick up a set.