Fitting Fuel Injector Rail After Replacing Head - HELLLLP!!! Please. - Alfa Romeo Forum
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(Post Link) post #1 of 11 Old 28-07-10 Thread Starter
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Fitting Fuel Injector Rail After Replacing Head - HELLLLP!!! Please.

At the risk of making myself look like a dumb a55 (nothing new lol) I think it's time to ask for some assistance.

A few weeks ago I took the head off my 2.0 TS CF1. Headgasket had gone and I sent it to be skimmed. Today, I finally got round to putting it all back together with a new headgasket. When I came to bolt the injector rail back on, the injectors didn't sit in their holes. The O rings just touch the top. As the rail and the inlet manifold are cast alloy, there is no room for adjustment. I remember when I took the rail off, the injectors "popped" out. Now it's been a long day and it could just be my brain is frazzled but can anyone tell me if I've made an obvious mistake or have I lost something, or; even worse; have I put something back incorrectly? I know it's difficult to diagnose without seeing it but if anyone has had this happen and knows what i might have done I would really appreciate you telling me.
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Have you used the right holes to bolt it down?

Take it off again, smear a bit of grease around the o-rings, and push them down into the inlet manifold. Then bolt it down...
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Have you used the right holes to bolt it down?

Take it off again, smear a bit of grease around the o-rings, and push them down into the inlet manifold. Then bolt it down...
Thanks for that Iain. I'm still baffled. I've just been to look at my GTV; which also has the CF1 engine; to compare it. They look identical apart from the fact that the injectors on the Spider don't reach the holes in the manifold. It's as if they have shrunk while being out.

I've rechecked the holes the rail is bolted on to and they are correct. I know it will be something really obvious but I just can't see it.

Still; it's a new day and I'm a lot more awake than I was last night, so I'm off out to spend the afternoon in the garage. Hopefully it will hit me in the face as soon as I look. Thanks again.
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The only thing I can think of is that you've got the rail the wrong way round!
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Thanks again Iain. I did think of that but I left the fuel pipes and injectors connected as advised in a "How to" post by smaky. I can only think that there must be some sort of additional "collar" between the injector body and the manifold (although the manual doesn't mention them) but I can't see how I could have lost 4 "collars".

I attached a photo showing no. 3 injector removed from the rail and inserted into the manifold as I think it should be and no.2 injector still attached to the rail. The rail is as far down as it will go but you can see from the photo that there is a gap of at least 10mm.

I'm tempted to go and remove the bits from my GTV, but that is at my daughter's about 12 miles away so if I can get any advice from the members on here, it would be appreciated.
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Looks like the injectors are pushed too far into the rail. I've got a fuel rail just removed from a CF1 engine at work, and comparing your injectors to that they are definitely too far into the rail. There is more than just one slot on the injectors where the clips slide into to hold them into the fuel rail. I would remove a clip, pull the injector out till you see another slot further up the injector body, re-insert the clip and try again. It is possible there is more than one slot in the injector bodies for the clips so the same injectors can be used in multiple applications.

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You could also remove the injectors from the rail, fit them into the manifold, then fit the rail to them....maybe!
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You could also remove the injectors from the rail, fit them into the manifold, then fit the rail to them....maybe!
Good idea, just might work
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Good idea, just might work
TBH, I'm not sure if you can get the clips on doing it that way round, but it'll give the OP an idea about where the injectors should be relative to the rail etc...
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Thanks guys. The injectors were too far into the rail. I knew it would be something obvious but don't remember taking them out of the rail when I removed them, so I don't know why they were too far in. Next problem is that I dropped one of the clips in the engine bay when I was making the adjustments. Now I can't find it so will have to try and source one tomorrow . I'm determined to have this running for the weekend. Really appreciate your input
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