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aerosurfer Samba Member
Joined: March 25, 2012 Posts: 1602 Location: Indianapolis, IN
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Posted: Wed Jul 27, 2016 12:42 pm Post subject: Fuel Injection Series Resistor Pack Reinforcement How-to |
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With the wire coming out of the Series resistor prone to breaking after years of vibration and heat cycles, I thought I would offer a tutorial for bracing and reinforcing the wire. This is not a repair per-se, as the part needs to still have the wires attached and working, but it will add support and protection at the solder joint. Its easy to do and took less than 20 mins.
First the part:
Noticed I marked the plug on the side that that center wire goes, with the ears
There are at least 2 body styles the spare one Im using has the larger aluminum case and a little tougher to reach the wire bases.
The other body style, which I believe is off a beetle has a smaller shell, but is otherwise identical, as seen on my own bus
Parts used
5mm heat shrink cut to about 1/4" length
Liquid tape
hobby paint brush
Heat gun
cotter pin or other piece to release the wires from the plug
Brake Clean or carb cleaner, to remove dirt and grease
To Start remove the wires from the plug, take your cotter pin and push the tabs down and pull out from the back side
Then we have this
What you see up close
Spray everything down and remove all the dirt, not really critical,, but always good practice
Paint the junctions with some liquid tape
Now slide over the Heat shrink right atop the base of the resistor
All shrunk down now
Now give the Plug a spray as well
Bend up the tabs on the ends so they lock into place on the plug
As said above, if you didn't pay attention to where the center wire went to, its in the middle closest to the side with the little ears. This one is going back into my spares, otherwise if I was using it would put a little bit of Dielectric grease on the ends
And all done, finished and now a stronger part
_________________ Rebuild your own FI Harness..My Harness
77 Westy 2.0L Rockin and Rolling Resto!
72 Sportsmobile (sold)
79 Tran$porter... Parts car money machine (gone) |
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SGKent Samba Member
Joined: October 30, 2007 Posts: 41031 Location: Citrus Heights CA (Near Sacramento)
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Posted: Wed Jul 27, 2016 12:51 pm Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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good work _________________ “Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin |
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Wasted youth Samba Member
Joined: July 06, 2012 Posts: 5134 Location: California's Hot and Smoggy Central Valley
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Posted: Wed Jul 27, 2016 1:22 pm Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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Solid thread, man! Nice work.
Bookmarked! |
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eche_bus Samba Member
Joined: October 07, 2007 Posts: 1318
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Posted: Wed Jul 27, 2016 4:51 pm Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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Great! Thanks! |
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Tcash Samba Member
Joined: July 20, 2011 Posts: 12844 Location: San Jose, California, USA
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Posted: Tue Sep 12, 2017 6:53 pm Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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Put in Tech Tips
Thank you
Tcash |
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KentABQ Samba Member
Joined: September 11, 2016 Posts: 2406 Location: Albuquerque NM
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Posted: Tue Sep 12, 2017 8:59 pm Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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Thanks for resurrecting this thread, Tcash. It's simple and effective. Ihave been wanting to do something like this but wasn't sure how best to approach it. Now it's on my (ever growing!) list of "To Do's". _________________ -Kent-
1976 Riviera, 1.8l FI chrome yellow VAN - "Chloe"
"I must say, how can you be in a bad mood driving this vehicle full of vibrant color.
Cars of today are so bland in comparison. It's like driving a celebration!" ---WildIdea
Bus ownership via emoticons:
---williamM |
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michaelctanner Samba Member
Joined: May 18, 2012 Posts: 21 Location: Germany
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Posted: Fri Sep 29, 2017 1:12 am Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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Hi fellow bus enthusiasts,
I‘ve got major problems coldstarting my 76 FI bus and noticed that one of the resistor wires broke off directly at the base, therefore not leaving any wire to solder to.
Does anyone know of an available replacement part that has the same resistance needed or is there a possible fix?
Original resistors have become hard to find (just like everything else) and Ìd prefer something I can easily replace a second time as I donˋt care for 100% originality.
Thanks for your help!
Michael |
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Wasted youth Samba Member
Joined: July 06, 2012 Posts: 5134 Location: California's Hot and Smoggy Central Valley
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Posted: Fri Sep 29, 2017 2:02 am Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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I do not know of an exact replacement part, but you might be able to measure the resistance of the resistor and shop online to find a replacement. But it probably would not fit the same just because of bad luck.
If you do find something that works, please post it to this thread so we can all have an option. |
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furgo Samba Member
Joined: September 06, 2016 Posts: 944 Location: Southern Germany
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Posted: Fri Sep 29, 2017 4:48 am Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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michaelctanner wrote: |
Hi fellow bus enthusiasts,
I‘ve got major problems coldstarting my 76 FI bus and noticed that one of the resistor wires broke off directly at the base, therefore not leaving any wire to solder to.
Does anyone know of an available replacement part that has the same resistance needed or is there a possible fix?
Original resistors have become hard to find (just like everything else) and Ìd prefer something I can easily replace a second time as I donˋt care for 100% originality.
Thanks for your help!
Michael |
If your resistor pack has kicked the bucket, I've got two suggestions:
• You can try to find a used one either for a bus or for another vehicle, with equivalent specs. I've had luck with finding L-Jetronic parts from Opel Commodores. I've got a Bosch #0 280 159 006 resistor pack (bus ones were 0 280 159 001) which is electrically identical and with the same mount. Alternatively,
• You can reuse the plastic connector housing and reuse the aluminum mount to fit newly bought power resistors in there. You should be looking for four 6 Ohm power resistors with 15W rating or higher (*). E.g.:
- https://www.tme.eu/gb/details/crl15w-6r2/15w-resistors/sr-passives/
- http://uk.farnell.com/vishay/rh0256r000fe02/wirewound-resistor-6-ohm-25w-1/dp/1369533
- http://de.rs-online.com/web/p/widerstande-durchsteckmontage/8459854
Alternatively, you might want to post a picture of your resistor pack. There are some very creative folks here at The Samba and someone might have an idea how to resurrect your non-solderable resistors.
Good luck!
(*) From a quick calculation on my head: each injector circuit: 14 V supply with 3 components in series - 1) series resistor 6 Ohm, 2) injector valve resistance 3 Ohm, 3) bipolar transistor switch. Gives ca. 1.5 A current consumption, which is in turn 13 W per resistor. Alternatively, if you dissect your broken resistor pack and take the resistors off, there might be a marking that tells you the exact wattage that was used originally (as it's not stated in the Bosch datasheet). _________________ '79 Westy, P22 interior, FI 2.0 l Federal, GE engine (hydraulic lifters)
Decode your M-Plate |
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furgo Samba Member
Joined: September 06, 2016 Posts: 944 Location: Southern Germany
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Posted: Sun Oct 22, 2017 8:10 am Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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Here's just another shout out for aerosurfer for the great instructions on refreshing and making the series resistor pack more robust.
I've just done mine and wanted to say thanks again.
Unfortunately, I don't have a "before" picture, but I'm sure everyone can picture a part covered in grease, dust and some rust
Other than using RTV instead of liquid tape (I didn't have any), the only thing that I also did was to clean up the rust from the crimped ends of the resistors with a rust remover gel. _________________ '79 Westy, P22 interior, FI 2.0 l Federal, GE engine (hydraulic lifters)
Decode your M-Plate |
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KentABQ Samba Member
Joined: September 11, 2016 Posts: 2406 Location: Albuquerque NM
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Posted: Thu Nov 28, 2019 6:46 am Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to |
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Thought I'd bump this thread of AeroSurfer's great idea since its been dormant a couple years.
I did this a few months ago as a preventive maintenance measure.
AeroSurfer's instructions and pics make it very simple to follow, and gives a certain amount of peace-of-mind after its done.
Highly recommend this for all Bay owners who haven't done it yet. _________________ -Kent-
1976 Riviera, 1.8l FI chrome yellow VAN - "Chloe"
"I must say, how can you be in a bad mood driving this vehicle full of vibrant color.
Cars of today are so bland in comparison. It's like driving a celebration!" ---WildIdea
Bus ownership via emoticons:
---williamM |
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