1.8T fuel rail fuel pipe fouls alloy inlet manifold - solutions?
 

I changed the inlet manifold on my 1.8T a few years ago, taking the steel fuel rail from my original (plastic) manifold and fitting to the new alloy manifold as part of the process.

At the time, I found that the bend in the original fuel rail fuel pipe fouls the body of the alloy inlet manifold. I had to bend the steel fuel pipe slightly to get the injectors to sit correctly in place, but this meant that the securing bolts to keep the fuel rail in place were off-centre and couldn't be used.

I've got my hands on a new fuel rail set and was wondering how others have overcome this problem? Could a plastic fuel rail pipe from a MG TF be swapped over? (these are straight and are meant for the alloy manifold). Or, do I just heat the pipe and bend carefully (similar to what I'd done before)?

Any thoughts much appreciated.

NOTE: Reason for the new fuel rail set is really only for the new injectors (to see if they will do anything for my misfire under load).

Cheers,
Karl.

Here's a few images, with the first two being of my current fuel rail which fouls against the body of the alloy inlet manifold; and the third of the new fuel rail set.

Cheers,
Karl.

:shrug: I haven't heard of this issue before - I've just recently rebuilt my Engine (with VVC Manifold) and had No Issue with the Fuel Rail.

Have you tried adjusting your Spark plug Gaps ? - It's a common issue to have slight misfire under full Boost with a standard 1.0mm Gap - best to have around 0.6mm (i think that is where mine are set) from my experience ;)



Paul.

Hi and thanks Paul,

Yes, I gapped my plugs to .7 or .75mm some time ago but it made little difference. I've also changed coils and HT leads before, with little effect.

I've not done much with the car (daily driver) these past 18 months or so as I've just been too busy :getmecoat:. But, I plan on having a mini-overhaul completed shortly. I have a new OEM turbo, downpipe, cat, auto box oil cooler and a set of auto box solenoids (having already changed gearbox oil with N402 - oil that came out looked decent, with no obvious swarf on drain plug - and I followed the MGR procedure).

I've had this misfire issue for a long time and whilst it may have gotten slightly worse unbeknownst to myself, the car still runs really well at standard throttle. It's only if I decide to use the throttle that it starts to panic..! The auto box upshift from 3rd to 4th happens far too early in normal driving once the car warms up, so that's why I get the feeling it may be gearbox related, but I think the car is starved of fuel under throttle and misfires have shown up on cylinders 1 and 4 (I think) from garage diagnostics previously. So, I'll see if new injectors help.

I don't mind changing the solenoids or the fuel rail, turbo and cat etc., but I'm certainly no mechanic and unfortunately, no local mechanics I know of are interested in tackling an old Rover that needs super specialist diagnostics equipment to identify troubles.

I think I'll be on my own doing this, but I don't really mind.. If I get it sorted, great. If I don't, well, it wasn't for the want of trying :)

Regarding the fuel rail, my original steel one definitely strikes the alloy inlet manifold body on my car - I wonder if this might be due to manufacturing variations, seeing as it doesn't happen all of them.. I'm fairly sure that I got it seated correctly when I was fitting it, but maybe not. I've seen second hand TF fuel rails online that are straight (these were the ones originally fitted to the alloy manifolds) - I wonder if it might be worth my while trying to swap over with the new injectors before fitting..


Cheers,
Karl.

I'll be watching this thread with interest as I too have that rare combo of 1.8T and autobox.

Have you checked there are no air/vacuum leaks?

Hi Richard,

Yeah, it's an excellent combo when all's working as it should. Unfortunately, mechanics these days seem extremely unwilling to do what I'd have thought was some relatively straightforward diagnostic work (for any decent professional).

I've checked all the vacuum hoses and don't see any issues with them. Plus, the misfire happens before any boost comes in i.e. at relatively modest throttle input. This makes me think it might be injectors, as the engine just feels "starved" when applying the throttle. Although there are some quirks to the auto box (change up from 3rd and 4th happens far too soon in normal driving + slight revving between 4th and top), I believe these are separate issues that will hopefully be helped by solenoid change + a complete ATF swap. The car had sat for the best part of two years before I started driving it circa 2010.

Just finding the time to carry out these tasks can be a pain..

Will definitely keep the forum (if not this thread) updated if I find any solution/s, though.


Cheers,
Karl.

Had you been having some troubles with the auto box in your car, Richard?

I seem to remember reading that someone changed their auto box ECU on here, recently. Was that yourself? If so, do you mind my asking, does any T4 or other programming need to be done to swap over the gearbox ECU (assuming one has the correct PRO14 version for the 1.8T)? And was the change of any benefit?


Cheers,
Karl.

I have the same set up courtesy of Trikey and the rail was not an issue ??:shrug:

have you checked for any Vacuum leaks at the Manifold ?

do you have a support Bracket/Brace fitted with the VVC Manifold ?


I'm sure a T4 session would determine any fault with the Injectors - are there any traders with T4 in your area ? :shrug:




Paul.

This is the first I have heard of this problem?!?