Fuel rails day 3

Today has seen significant progress on the build, finally. 

I ended up having to remove the power steering pump and also the battery to enable me to gain access to the lower fuse box area so that I could disconnect the final two wiring loom connections. There was also a little camshaft position sensor hidden away at the back as well on the passenger side, read of the engine. Glad I didn't just yank it out!

The air con also had to be removed however I was able to slacken the belt and remove the lower pulley, allowing me to simply move the compressor and bend the lines back without having to vent the system totally. 

The picture above shows the air con compressor moved over to the headlight area.

Once the manifold is out, its a good idea to stuff some rags down the ports to protect the valve stems while you clean the gasket mating surfaces. 

The two pictures above show how the injector O'Rings had started to fail and were actually working their way down towards the nozzles. Not good. 

The picture above shows the underside of the inlet manifold removed but with the fuel rails and wiring loom still attached. It was actually quite an easy job removing them, if you take your time. 

As you take the lines off, its then easy to remove the actual rails themselves. You have to make sure that as you take them off, you remove the injectors carefully and and label them!!!! They have to go back into the same port!!

Once everything was removed, you can see the wiring loom on the left and the manifold on the right. Its a good idea to give everything a clean once off as its easy to paint the manifold now!

Good planing ahead means you don't have to keep flicking through the manual every 5 minutes either

The garage quickly gets taken over with parts and notes, so its a good idea to label everything and then make plenty of notes as you go. 

The picture above shows the new rails fitted, without the injectors. Im waiting on new O'rings to arrive so I thought I would just test fit them. There are a couple of possible ways to go on so its best to chill out and double check everything, twice. 

The work has sort of halted now until the O'Rings arrive, which shouldn't take too long, but once here, its simply a matter of fitting all the wiring loom back to the manifold and putting it back in place in reverse order, then getting the car mapped again.