LarryF_in_Ca

Here is a simple write-up from my attempt to rebuild my Fuel Distributor. The FD is made up of two halfs with a cylinder that is in-between the two halfs.

From the first picture, I replaced all the inside O-rings and then simply installed the inside cylinder into the top half of the FD. Note that the small clips that the rings are holding on can actually be "slid" in and out. I slid them out so that the rings had a good grip, when I pushed in the cylinder, the rings stayed put. Realize that there are five rings for the five cylinders.
<img src="http://pictureposter.audiworld.com/48496/fd_inside_orings.jpg">

This picture, I show the cylinder being inserted, note the position of the rings, they are inline with the fuel cylinder ports.
<img src="http://pictureposter.audiworld.com/48496/fd_inside_core.jpg">

Here is a picture of the Port springs and seats that are inserted into the fuel ports, which will be covered by a thin metal diaphram. It is the spring and the diaphram that control the fuel pressure to the cylinders as well as applying pressure to the inside fuel plunger. I simply cleaned off the metal diaphram with carb-cleaner and installed the springs and seats in the same location that I found them.

The bottle in the back ground is Indian head gasket shellac.
<img src="http://pictureposter.audiworld.com/48496/fd_port_springs.jpg">

This picture shows the top-half with the internal cylinder in place and port springs ready for the bottom half.
Note: The cylinder is where the plunger moves and displaces the fuel mixture, this is how the fuel distributor does it's magic.
I coated both the top-half and the bottom half of the distributor with a really thin coat of Indian Head Shellac.
<img src="http://pictureposter.audiworld.com/48496/fd_upperhalf.jpg">

This last picture shows the top-half and bottom-half joined together. I simply placed the thin clean metal diaphram in-between the two Shellaced halves. I used a cross-hatched pattern when I closed the halves together, with a final torque of around 20 foot lbs.

<img src="http://pictureposter.audiworld.com/48496/fd_finished.jpg">

I have yet to install the FD, that will be another day, but overall I was able to get the plunger un-stuck and It seems good as new, I'll keep you all posted.

Final price:
Indian head Shellac $2.00
O-rings $5.00
Total rebuild about $7.00
Not bad, hope it works...

RussB

I hope that it works.

If so, you've saved yourself many hundreds of dollars, as last I checked, a new fuel distributor sells for the better part of $1000.

rooster 2

Your story is the first write up that I have seen on a rebuild of a fuel distributor. The Haynes book, and maybe even the Bentley, say not to open the fuel distributor, claiming there are no user parts available.

icon73

nice write up, let us know how it works once installed.

thanatos

where did you get the o-rings ? Any o- rings , special rubber,or from audi supplier only ? o- ring sizes- do you rememmber ? it's nice to have them first before I take mine apart...

LarryF_in_Ca

Thanatos,
I used (8mm ID x 12 mm OD x 2mm thick) o-rings from a maker called SERV A LITE PRODUCTS, East Molene, IL.

For more information check out the following site, here a fuel distributor for a Porsche is being rebuilt.

http://www.cfmstudios.com/928fueldistributor/

With regards to the o-rings, it is kind of a hit and miss, you actually need to open up the fuel distributor and find some that fit by trying them on...

LarryF