Hello, I'm rebuilding the engine on my son's 1993 FD, and the previous owner gave us a new powder coated lower intake manifold that we'd like to use. However, it looks like the new LIM is setup for non-OEM fuel injectors, so I'm not sure if I can use it and would like some advice.

Old LIM measures ~16.3 mm bore, new LIM looks to have an insert with ~14.0 mm bore. OD of insert on new LIM looks like ~16.8mm, so might just be a pressed insert into a stock casting.

Any suggestions here? Not sure I want to go to a new type of injector as I'm generally trying to get back to stock. Could maybe try and pull the inserts out of the casting but that seems optimistic. If needed I can clean up the old LIM but that seems a bit sad.


Old LIM Fuel Injector ID

New LIM Fuel Injector ID

New LIM Fuel Injector OD

 

Those are sleeve inserts typically use for an aftermarket secondary fuel rail. If you are going to use the stock injectors, then simply pull these out. You can see one of the o-ring that seal it to the LIM in your picture. If you are going to rebuild everything stock, then again pull these out. If you are going to modify the car for more horsepower, then you might want to leave these in and purchase an aftermarket fuel rail so you can upgrade the secondary injectors. The stock secondary injectors limit how much you can modify the car before you run out of fuel at the high end of the power band.
Mike

 

Thanks @mikejokich . I'll try pulling them. It looks like the LIM was powder coated after the inserts were installed so I might need to cut the paint. Is there a clever tool or something for pulling those? I did try inserting a dental pick and pulling from behind, but can't get much force that way. There's also nothing threaded to grab onto. If no good ideas I'll figure something out creative this weekend.

 

There's a possibility they're installed with something like retaining compound.

Normally a bit of heat to break the bond in that case would be the suggestion. If you dont want to risk the powdercoat, I'd probably try to tap the inserts and see if you have any success with a slide hammer.

Unless running all the anti pollution stuff and stock ecu as a requirement, modern injectors instead 30 year old ones might be worth a thought.

 

If there enough of the adapter sticking proud of the manifold casting you can try to gently get a grip with channel-locs or similar and try to twist the insert, protect with a rag if you want to keep the inserts. The o-rings are likely dried out/glued to the manifold along with being tightly press fit.

 

I went with the slide hammer approach and it worked great - I bought a $20 bearing puller kit from Amazon and the smallest collet fit in behind the adapter snuggly. Seems like most of the holding force was really just the powder coat that seeped down between the adapter and LIM. I cut around the edge of the adapters first, but still some powder coat still chipped off. Thanks for all the advice - excited to use the pretty LIM on my rebuild!

 

Where, I wonder, did the little bits of powder coating fall into?

 

The manifold appears to be not mounted on the engine so I don't think there is concern for particles entering the engine.