Ok, I give. How do you get the 1650 secondaries to seal in the LIM on an S5? My car is an 88 and on my S4 manifold it seems like the o-ring sits tight on the housing. On the S5 manifold there is no way the KG rail can bolt down as the injector is standing up off the diffusers. Pull the diffusers out and the injector flops around like a wet noodle.

 

kg parts makes spacers for the 1600cc injectors but it says they are for FD's. maybe you need them or need different o-rings.

http://kgparts.com/index.php?page=diy

 

I have the KG secondary rail on an s4. I'm trying to understand your problem... Are you trying to keep the Bosch lower o-ring and pintle cap? Hopefully this also works on an s5, but your best bet is to remove the o-ring, pintle cap, and orange thingie on the Bosch injector. Install an S5 pintle cap (available from Mazdatrix for like $2 each) over that, and then the Mazda OEM injector grommet so it can seal into the LIM. If the rail won't bolt down tightly, try to stack two M10 wasters between the holes on the rail and the LIM. With two washers stacked, use allen head bolts, M10 x 1.25 x 25mm long I believe. No spacers were needed for this setup and I had no fuel or vacuum leaks. This is the setup I ended up using to make it all fit on my 882 T2, no thanks to rx7store which sold me a fuel system kit with no mounting hardware...

So it should go allen head --> mounting holes --> 2 washers --> LIM .

and the injector itself should just have the upper o-ring which seals into the rail, then the OEM injector grommet from your stock injectors, then an s5 pintle cap.

 

Are you trying to swap different series fuel rails?
Is that what you're asking?

You need to keep the fuel rails and intake manifolds the same series.
You cannot mix-n-match them.
The spacing for the secondary fuel rails is different between the series.


-Ted

 

Aspec sold me the correct rail for an S5 manifold.

I was trying to figure out what the deal was with the manifold side of the injector to get it to fit. As argx was saying the bosch injector obviously will not fit into the stock base. I have S4 injectors, can I swap the pintle caps from them? How does it come apart?

 

Do you still have the air bleed valves inside the LIM?
These help seat the stock fuel injectors.
The lower grommet seals the bottom of the stock fuel injector to the LIM.
The Bosch 160 lb./hour fuel injectors are not the same dimensions as the stock NipponDenso fuel injectors.

Changing pintle caps should not change anything.


-Ted

 

and use the OEM injector grommet. It worked on my s4. The s4 pintle cap will not work, it is a lot thinner than the s5 and you will still have a vacuum leak. Trust me, I tried.

 

Again, the pintle cap is not design to seal the tip.
I use cut pieces of 10mm silicone vacuum hose to seal the tip.


-Ted

 

Another load of bad info from the Tech Advisor, the injector spacing is the same bewtween the S4 and S5 both are 5.64" between holes on the LIM. Rail seating height is different which can easily be overcome with spacers when using the S4 rail on the S5 engine.

The lower grommet & pintle cap are responsible for all the sealing of the injector, this is accomplished by a tight seal around the pintle cap. You can do it the correct way and change out the pintles to S5, and use the factory S5 gromments or you can half *** it with a piece of fuel hose that has the potential of blowing out of the manifold or worse yet being sucked in.

 

Pics comparing the S4 to S5 rails, notice the injector spacing is exactly the same. The mounting holes are also exactly the same.

Next are pictures of the S4 vs S5 injectors, the S5 pintle cap is much smaller than the S4. The S5 is a perfect replacement for the Bosch 1600 injector and allows for easy installation into the LIM.

Next pic is the S4 rail with S5 injector on the S5 LIM just to give an idea of the fitment and alignment.

Ted- Do the research before posting your bad useless info.

I have a feeling I will be typing that alot now that I am paying attention to what Ted is "advising" people

 

I run an S4 rail on my S5 mani's with two washers under where the rail bolts to the LIM. Fits perfect, no leaks, driven across the continent with 1600's in there. On my 1600's I did exactly what is shown on the rx7.com webpage. I cut that original pintle off, slide the stock (s5) pintle on, slid the stock oring on, and had to grind a little bit on the top of the injetor to allow it to push further into the rail.

Thats it, fit fine, no leaks.

EDIT: noticed banzai already covered this oops...

 

Ok so carefully cut the cap off with a dremel at the spacer ring just above the O-ring.

Order a pair of S5 pintle caps and lower gromet

Keep the S5 air bleeds in the manifold

 

I find it funny that I never ran across any posts on this in all my years on this forum.

 

i am also using the s4 rails w/ s5 intake manifolds and just have 2 washers under the rail. as long as the lower grommet is sealed properly there shouldnt be an issue.

 

Flat head screwdriver will pop them off, no need for anything as aggressive as a dremel.

There have been a few other threads with this info in them. Arghx was dealing with this a few months ago and I gave him this info then.

 

cool. Thanks guys. Looking forward to hearing the pitterpatter of 2 happy rotors

 

i love how RETed and Banzai are constantly in a war...

these guys are both quite replete with knowledge and they both seem to hate each other

rx7 drama yeah kidzz