syoo8

Colin, thank you for your suggestion to get crow's feet wrenches. They worked in getting the fuel line off the fuel cooler, and a Greg Brown replacement onto the fuel cooler.



It was rather warm today so I spent some time in the garage, installing the intake runners.



When I put the fuel rails in, to my chagrin, the fuel rail did not line up- at all- with the fuel pressure regulator.



Is this a common problem when reinstalling fuel rails? What did I do wrong here?

Bertrand Daoust

Not a common problem.
Took a look at mine yesterday (intake removed) but can't see anything wrong in your picture. Sorry.
I'm sure someone here will find out.

Here's a picture of mine without he fuel rail before the intake removal.

Rob Edwards

The thick 'wave' washer at the base of the FPR looks like its big nut is not compressed- is that nut loose? That might move the FPR back a mm or 2. And you can bend its L-shaped bracket.

The ball end on the fuel rail gives you a little flexibility, but not much- shouldn't have to force it too much!

syoo8

Betrand and Rob,

Thank you for your replies.

For other newbies out there:

I loosened everything and tried again. I don't think there is any secret, I just jiggled things until the "ball" from the fuel rail mated with the "cup" of the fuel pressure regulator. Before screwing them together, I applied a thin coat of Drei Bond to the "ball" part of the fuel rail, to prevent leaking.

Then, I tested the integrity of the fuel system. I pressurized the fuel lines/rails by removing relay IV and cranking the starter. Jim Bailey suggested it in this thread.

In this thread, he says:

Anyway, the first time I pressurized, there was a small leak at the front of the 1-4 fuel rail, because I hadn't screwed Greg Brown's line in tight enough. After securing it, I pressurized again. I rubbed my fingers around the circumference of each junction and then smelled them. No gasoline smell. I will try again tomorrow, but hopefully we're all good there.

syoo8

One of the fuel lines I replaced was Greg Brown's line between the fuel pressure regulator (on the passenger side) and damper (on the driver's side.)



I had to make sure that it was oriented correctly- otherwise it would kink. I managed to orient it in a way that 1) it wouldn't kink, and 2) wasn't touching anything.

syoo8

After testing the fuel system, I put the intake side plenums on. It looks easier than it is, because it is kind of a pain to get the rubber gaskets around the tubular openings for the side plenums. What I ended up following was this procedure:

1) Put two hose clamps on runner, loose.
2) Put gasket on intake runner, but not all the way- keep it loose.
3) Put a bit of some lubricant (I used 303 Aerospace Protectant.)
4) Repeat for all five gaskets (on each side.)
5) Push side plenum into gaskets, being careful that the gaskets don't fold.
6) Align two hose clamps on each gasket, making sure that the hose clamps lie in the "groove" that each gasket provides.
7) Tighten carefully.

syoo8

I am frustrated. After attaching my "test rig" to the MAF and pressurizing, I can hear an air noise- but I can't see/hear/feel where it is coming from. The test rig's meter doesn't show any pressure whatsoever. I have a feeling some hose has come loose, I don't know where it is, and I have a sinking feeling that I am going to have to disassemble a ****load of stuff.

Lizard928

Just pull the boxes and center tube off. Bet it's the hose that connects to the center tube.

syoo8

Hi Colin,

I pulled off the boxes and the center tube. The hoses that connect to the center tube were securely on there, as was everything else that I could inspect.

Now, the problem is I can't get the center tube back on. It is a very tight fit. Do I need to remove the fuel rails and runners to get the tube back on?

syoo8

Well, I was in the garage today, panicking, unable to get the center "T" back on. A quick post to Rennlist here and I got the "T" back on.

I filled it up with coolant and noticed some coolant dripping. When fiddling with the fuel pressure regulator/fuel pressure damper/ "U" fuel line and the fuel rails, I left everything loose. I forgot to tighten two 13mm bolts that hold down that hold down the FPR bracket. I noticed it quickly so didn't lose much coolant.

Lizard928

Did you find the intake leak?

syoo8

The good news is that the intake refresh is done. (Sort of.) Here are some pics.

(After taking the pics I noticed that the three-way right above the cross bar slightly to the right of the oil filler was disconnected. I reconnected it.)

syoo8

The bad news is that my car is whistling badly when running. Either that, or there is a miniature jet engine that crawled inside my 928S.

Whistling Sound MP3

Colin, when I spoke with Roger today, he said that pressurizing the intake through the MAF (as I tried to do) would be useless unless the engine was at TDC, he advised me to just try to start the car.

Anyway, I hope that it is an air leak, although I can't imagine where.

Thoughts?

Lizard928

Regardless of the position of the engine there will always be a pair of intake valves open. So you will have SOME leakage past the rings, but not that much......

Sounds to me like you have a leak somewhere.

PC-85-928S

Make sure none of the rubber intake sleeves are not pinched on the bottom. Sometimes you can not see it from the top.