1600cc Bosch RX7 Fuel System Upgrade
I have noticed that a possible amount of 3 stock o-rings can fit on the 160 lb/hr 1600cc BOSCH fuel injectors after the grommet is in place. Do you think tripling up the o-ring seals would be a bad idea? I don't think so. I'll try it.
Stock 550cc 1600cc with cap on bottom
The goal is to make the Bosch 1600cc fuel injector on the right to match the stock RX7 fuel injector on the left. You can use a dremal cutting tool to trim the two upper plastic ribs off. Be very careful not to nick the metal shaft and gouge it. This will cause a bad seal and result in leaking. I will be using 3 o-rings instead of one in the picture above. I would just hate to see an engine fire AGAIN!
1600cc trimmed 1600cc trimmed o-ring
stock o-rings & seals
Next, take out the green o-ring in the left picture above with a razor. Insert all of the stock o-rings in their correct order. The upper gap that holds the 11mm stock OEM Mazda o-ring can hold three. Leave the orange spacers against the bottom plastic (yellow) instead of against the body of the injector where it was. You can use the image on the right (above) to see the color scheme.
1600cc finished Stock 550
Here are images of the o-rings with the VW rabbit assisting int he spacing and sealing. In my opinion, it works even better than the above modification!!!!
Here is a rewrite if what I did than the above modification:
On the upper
From bottom to top. I did the dremal mod to the injector.
1 (82/84?) (it's green) VW o-ring at the base, then 3 stock o rings on the other side of the lip.
The green VW o-ring has a tight seal on the injector on the inside and on the fuel rail upper, but lower it might now seal well, but doesn't matter since the inner is sealed. I guess with the VW injector seal and the stock seals, this kind of works like a double seal with the addition of 2 more stock injector o-rings.
And, NO LEAKS!
I tried the mod with just 1 stock seal, and the seal leaked like a chopped up garden hose. Pretty scary how it sprays all over the engine bay.
AN fitting are welded to rails.
I chopped off my fuel rail ends, tapped them to 5/8 thread, and put some aluminum -AN fittings on them and had them welded for $30 with a TIG. Can't beat that! Then I paid $75 for socketless fittings and hose stuff. ouch!
NOW GO HAVE A BEER!