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Old 04-14-2021, 07:26 PM   #1
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986.2 injector retrofit

Up until now, replacing the pre '03 986 fuel injectors required either shelling out tons of cash for remanufactured injectors or sending them out for cleaning and calibration by a third party. But my friends, I am here to tell you that this does not have to be the only way!

The 986.2 injectors are made by bosch, are more fuel efficient than the 986.1 part (supposedly), and beat of all run $30 a piece on some sights. So what gives? Why weren't they retrofitted back into 986.1s? Commercialism!

Check out the pics below. The only thing preventing installation of these injectors into the pre 03 cars is the lack of the notch that the square shaped c clip (which fastens the injector to the rail) slides over. Interestingly there's actually a scoring in the plastic located exactly where the groove needs to be, but the groove wasn't cut. But this, of course, is why God invented dremel tools.

It takes about 3 min per injector to do the necessary modification. Using a fine tip dental style bit on the dremel, first score the plastic where the notch needs to run (along the convenient line that's already present) and then go back a few times and slowly deepen the groove until it's as deep as the one already present. That's it! I did give them a good washing in gasoline after this to get all the little plastic particles off them and make em look real nice nice.

Once you have done this, they will install just like the oem injectors. I'll outline that process real quick because I haven't seen a great description of it (pelicans pics are good but the process description is a bit, uh, lacking) and so I winged it, but there is definitely a right order to do things.

Removal is easy - undo wiring harness from clip and wrestle it somewhat out of the way, remove two bolts per rail holding them onto the manifold, then the c clips pop forward with a flathead screwdriver (don't try to completely remove them, they won't fit out yet) then the rail pulls off the injectors and c clips are free. Next undo the wiring clip from the injector using a flathead screwdriver to pry the metal clip away from the plastic connector. Be careful here, just pop the clip back, don't force it completely out. Trust me on this one. Lastly, wiggle out the injectors (and make sure you have the orings on both ends of every injector).

Now for install - this is where the order of steps is critical. Mount injectors into the rail and insert c clip to secure in place. Try to not foul up the ends of the injector while doing this (easier said than done). When all 3 injectors are mounted in the rail, insert them into their receiving holes on the head. You do this with the rail and injectors as a unit, so to speak. One they are all seated, replace the two bolts and connect the wiring harnesses. Then repeat on the other side. Magnetize your socket before replacing those two bolts, if you can. Thank me later for that lil "pro tip".

The only thing that isn't perfect about this is that the 986.2 injectors are free to rotate in the c clip, but I can't see that being an issue. I haven't driven her yet but I did start her up and had no leaks on either rail.

I will say one thing about this process - my air box, sai pump, and engine bay fan have all been deleted so there's quite a bit of working room on either side of my motor but damn if it still isn't close quarters (I have bear paws for hands though). If the air box and SAI were still there, I truthfully don't see how it would be possible to do this.

Anyway, I hope this helps someone save a few bucks, and maybe even save a few drops of gas and squeeze out an extra pony or two in the process

Best,
Ike

First pic is 986.2 (unaltered) on the left, 986.2 on the right.

Second pic is 986.2 injector with the needed groove cut into it.

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Old 04-15-2021, 11:22 AM   #2
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Might need to do a video for my channel... good job!
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Old 04-15-2021, 04:56 PM   #3
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Thanks man!

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Old 04-23-2021, 08:59 AM   #4
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Any update?
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Old 04-23-2021, 12:12 PM   #5
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200 miles on them so far, they run flawlessly as far as I can tell

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Old 06-29-2021, 07:27 PM   #6
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Second update - new injectors still working flawlessly. And, as added bonus, better gas mileage! Previously I would get 230-240 miles to the tank, but I am now consistently getting 260-270! Not too shabby eh?
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Old 06-30-2021, 05:23 AM   #7
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Thank you.......
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Old 06-30-2021, 09:27 AM   #8
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Quote:
Originally Posted by ike84 View Post
Second update - new injectors still working flawlessly. And, as added bonus, better gas mileage! Previously I would get 230-240 miles to the tank, but I am now consistently getting 260-270! Not too shabby eh?
Have you figured out miles per gallon????
I consistently get 23-25 miles per gallon.
It is a 2000S stock.
So a full tank is 16 Gal. if I remember right.
I can go around 350 then the fuel light comes on.
That happens at around 14 gal. I think
So I can get close to 400 miles per tank
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Old 06-30-2021, 06:53 PM   #9
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Have you figured out miles per gallon????
I consistently get 23-25 miles per gallon.
It is a 2000S stock.
So a full tank is 16 Gal. if I remember right.
I can go around 350 then the fuel light comes on.
That happens at around 14 gal. I think
So I can get close to 400 miles per tank
Holy cow, that's way better than mine. My tank holds 15 gallons. I was getting 16-17mpg before (mixed highway and City) with original injectors, 17-18 now (majority of driving is 80-110mph at 4-6k rpm with a lot of wot)

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Old 06-30-2021, 06:54 PM   #10
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Thank you.......
You're welcome, I hope this helps out down the road!

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Old 06-30-2021, 09:25 PM   #11
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Originally Posted by ike84 View Post
Holy cow, that's way better than mine. My tank holds 15 gallons. I was getting 16-17mpg before (mixed highway and City) with original injectors, 17-18 now (majority of driving is 80-110mph at 4-6k rpm with a lot of wot)

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Your driving style has lots to do with your gas mileage.
WOT dumps lots of fuel tell the RPM catches up with engine load.
But it is fun

I play with mine some too

I think if I took say a 350 mile run under the right weather and road conditions I could get 28 mpg maybe 28.??? mpg If I really concentrated on gas mileage.
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Old 07-10-2021, 08:15 PM   #12
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Nice work. Just wondering if hand fashioned groove affects sealing to the rail..?

I suppose changing the whole rail and injectors would be a no go? I have never touch anything but the fuel filter in the fuel system so I have no idea.
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Old 07-12-2021, 08:41 PM   #13
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Nice work. Just wondering if hand fashioned groove affects sealing to the rail..?



I suppose changing the whole rail and injectors would be a no go? I have never touch anything but the fuel filter in the fuel system so I have no idea.
That groove holds little circlips between the injector and the rail to prevent the injector from rotating on their seat. The rail itself holds the injector to the motor, and the seal is purely a factor of pressure from the rail on the orings, so I don't see a chance of leakage.

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Old 07-28-2021, 01:30 PM   #14
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But … what about just fitting the newer rail?
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Old 07-29-2021, 09:20 AM   #15
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But what about just fitting the newer rail?
The 986.2 rails are a returnless system with the pressure regulator in the fuel tank...have fun with that!
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Old 08-05-2021, 09:53 AM   #16
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Originally Posted by ike84 View Post
The 986.2 rails are a returnless system with the pressure regulator in the fuel tank...have fun with that!
Question answered

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