A few solutions to poor plastic URS engine parts

[vwnut8392]

I've been plagued with broken throttle cable catches and pain in the butt plastic injector cups for too long. the replacement parts both OEM and aftermarket are expensive and sometimes hard to find so i've created cost effective and durable solutions to these problems.

The first is the throttle cable catch. its made from stainless steel and is press fit with a locking bolt to keep it in place. i've installed them with red and blue loctite to make sure they stay in place.









The second part is those pesky and over priced injector cups that never ever come out, crack, chip and break. well my solution is stainless steel and aluminum injector cups.










Once i test these parts i will be producing more for sale if anyone has any interest in them.

[UrS4boy]

Not wanting to be negative but there could be a good reason why Audi went for plastic injector inserts over metal. One reason could be cost, e.g. plastic could be cheaper than metal. The other reason *might* be heat transfer. The plastic ones would transfer less engine heat to the injectors than metal ones.

I just changed mine old plastic ones last year and I agree that getting the old ones out without breaking them is impossible (because they do get brittle with that heat).

Did you machine a seat on the inside of the metal insert for the O-ring to sit? I just can't see it from your photo.

My intake insert post:

http://forums.quattroworld.com/s4s6/msgs/266127.phtml

My solution to sealing the insert so there is no boost leakage:

[vwnut8392]

Yes they are identical copys of the original plastic ones for the most part. im actually working on aluminum weld in injector cups too so once their in there and welded in place you'll never have to worry about sealing, cracking or breaking ever again. i dont heat being a problem really. they make these for 1.8T's now out of billet aluminum and i went through the feed back on them and not one person had a negative thing to say about them.

[irishs2]

Great work there.



The are also available in brass from Audi, so heat conduction might not be a problem.

[macspring]

While the pros and cons of plastic have been covered, what are the pros and cons of the brass ones ?

Whats the part number ?

How much ?

and which car / engine did Audi fit them to ?

Good useful / thread.

Thanks.

[macspring]

@ OP, the other plastic bit that I can think of right now that breaks on a UrS6 is the two small respective plastic guides for the bonnet pull cable, on the 'inside' of the bonnet slam panel.

Don't know if they've gone on your car.

Admittedly, they may not be relevant or worthwhile doing anything about as one can use a zip tie / tie wrap instead as a good ghetto fix.

Not sure if the original part is still available new from Audi / Audi Tradition ?

[UrS4boy]

The are also available in brass from Audi, so heat conduction might not be a problem.

I am sure if you check deeper, the brass inserts were for the mechanical injectors, i.e. those used on the CIS and KE-Jetronic, pre-Digifant systems.

[macspring]

The bonnet pull cable and the two female latches, and the male spuds on the bonnet are worth checking now for how they should work, and how they are actually working right now after x number of years.

Grease and fine tune the mechanism in a pre-emptive manner to avoid something snapping and leaving you with the grief of a bonnet jammed shut at generally the right wrong time.

This applies to both B4 and C4 cars.

Back on topic.

[UrS4boy]

Hood Release: How it works, why it fails and how to fix it

@ OP, the other plastic bit that I can think of right now that breaks on a UrS6 is the two small respective plastic guides for the bonnet pull cable, on the 'inside' of the bonnet slam panel.

Besides NEW parts, there are several very serviceable DIY solutions for that problem, as documented here:
Hood Release: How it works, why it fails and how to fix it:

http://forums.quattroworld.com/s4s6/msgs/41331.phtml

[vwnut8392]

My S6 has 255,000 mile so their broke lol. I have some mechanics wire rigged up on my hood cable hahaha.

The brass cups are indeed for CIS mechanical fuel injection cars and will not work with an electronic injector.

[macspring]

The brass cups are indeed for CIS mechanical fuel injection cars and will not work with an electronic injector.

Is the 'not working' only because of the fit of the injectors is different, rather than any inherent difference in the operation of an older type mechanical injector versus the S6 electronic injector ?

Just curious as I like the idea of better than oem injector cups that won't leak in air, irrespective of the material they're made of.

[UrS4boy]

Is the 'not working' only because of the fit of the injectors is different, rather than any inherent difference in the operation of an older type mechanical injector versus the S6 electronic injector ?

The early mechanical injectors, like the 035133551F on a 10V MC turbo engine, are "pencils", in comparison to our electronic injectors.

035133551F:


The 20VT style injectors:

[macspring]

Nice reply, with photos Dave.

Agreed re the physical fit, but what about any negative issues arising from using a metal insert instead of a plastic insert on an I5 20vt engine was the underlying second part of the question.

[vwnut8392]

Well guys i got a few of these punched out and ready to go! so for anyone who owns a broken throttle cam here's the cheapest solution out there hands down! 30.00 bucks shipped inside the USA and for international shipping message me and we'll work it out. Im going to powder coat one or 2 of these to see how they turn out, one in matte black and one in another undecided color.

[HenryG40]

Will take a throttle clip, and extremely interested in the metal injector inserts.