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Fuel Injection Series Resistor Pack Reinforcement How-to
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aerosurfer
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PostPosted: Wed Jul 27, 2016 12:42 pm    Post subject: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

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:
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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

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Parts used
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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

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Then we have this

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What you see up close
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Spray everything down and remove all the dirt, not really critical,, but always good practice

Paint the junctions with some liquid tape
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Now slide over the Heat shrink right atop the base of the resistor

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All shrunk down now

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Now give the Plug a spray as well

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Bend up the tabs on the ends so they lock into place on the plug
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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
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And all done, finished and now a stronger part

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SGKent Premium Member
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PostPosted: Wed Jul 27, 2016 12:51 pm    Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

good work
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Wasted youth
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PostPosted: Wed Jul 27, 2016 1:22 pm    Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

Solid thread, man! Cool Nice work.

Bookmarked!
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eche_bus
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PostPosted: Wed Jul 27, 2016 4:51 pm    Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

Great! Thanks!
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Tcash
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PostPosted: Tue Sep 12, 2017 6:53 pm    Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

Put in Tech Tips
Thank you
Tcash
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KentPS Premium Member
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PostPosted: Tue Sep 12, 2017 8:59 pm    Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

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".
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michaelctanner
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PostPosted: Fri Sep 29, 2017 1:12 am    Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

Hi fellow bus enthusiasts,

Ive 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 d 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
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PostPosted: Fri Sep 29, 2017 2:02 am    Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

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
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PostPosted: Fri Sep 29, 2017 4:48 am    Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

michaelctanner wrote:
Hi fellow bus enthusiasts,

Ive 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 d 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).
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furgo
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PostPosted: Sun Oct 22, 2017 8:10 am    Post subject: Re: Fuel Injection Series Resistor Pack Reinforcement How-to Reply with quote

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.

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Unfortunately, I don't have a "before" picture, but I'm sure everyone can picture a part covered in grease, dust and some rust Smile

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.
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