Successfully removed engine - injectors sprayed gas?? - 986 Forum - The Community for Porsche Boxster & Cayman Owners

bg305 · 09-06-2021, 05:10 PM

I just successfully removed the engine from my boxster. Overall everything went well. As I am rolling the engine and tranny on the hydraulic cart away from the car I noticed a strong gas smell and that bank 2 looked wet. I took a video and attached..

https://youtu.be/3jxOPLhZeec

Anyone seen this before (my first engine removal). Did i maybe catch the rail on something when separating the car and engine? (I did not notice if i did). I did catch the stupid power steering pump lines on the e-brake cable on the left side.. but otherwise I thought it was a clean drop.

Quadcammer · 09-07-2021, 05:09 AM

thats a new one. Looks like the clips are still in place, so odd that they would be leaking, especially since they are no longer under pressure. I'd probably just replace the injector o-rings, reassemble, and when you first start up the new/repaired motor, watch closely for fuel leaks.

ike84 · 09-07-2021, 05:54 AM

Agreed with quad, that doesn't make any sense. When these injectors fall they tend to stick open, but that's no reason why they should leak with the rail still assembled... Unless that's just fuel running out from the rail where the return line was disconnected and down the injectors by gravity.

I didn't try but Wayne's writeup says o ring replacement can be tricky (it's easy to damage the tips). You may just wanna swap to all new 986.2 injectors.

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bg305 · 09-07-2021, 08:15 AM

Thank you for the input!
After a bit of sleep and a small bit of forensic investigating this morning, I believe that one of lines I snagged was not just the power steering line but also the fuel return (in my head at the time there were 2 lines so I thought of the 2 power steering lines, but the return line for that looked fine and was just the soft rubber type. Snagging the return fuel line, I can see that would pull the rail upwards and away from the injectors. I will not have time to get deeper yet but I am pretty sure that is what happened. Hopefully re-seating everything and new o-rings will be enough and I did not bend the rail or mangle the injectors.

ike84 · 09-07-2021, 11:34 AM

Quote:

Originally Posted by bg305

Thank you for the input!
After a bit of sleep and a small bit of forensic investigating this morning, I believe that one of lines I snagged was not just the power steering line but also the fuel return (in my head at the time there were 2 lines so I thought of the 2 power steering lines, but the return line for that looked fine and was just the soft rubber type. Snagging the return fuel line, I can see that would pull the rail upwards and away from the injectors. I will not have time to get deeper yet but I am pretty sure that is what happened. Hopefully re-seating everything and new o-rings will be enough and I did not bend the rail or mangle the injectors.

The only way that you could have pulled those injectors out while the rail is still attached is if you deformed the rail enough to pull the injectors out of the head cover.

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Homeoboxter · 09-07-2021, 10:02 PM

Quote:

Originally Posted by ike84

The only way that you could have pulled those injectors out while the rail is still attached is if you deformed the rail enough to pull the injectors out of the head cover.

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This sounds likely to me too. If you pause the video at 0.08 it looks like the socket on the rail where the injector goes into and the injector are not in line... Any damage on the rail indicating it got pushed sideways while pulling the engine?

bg305 · 09-17-2021, 08:09 AM

Quote:

Originally Posted by Homeoboxter

This sounds likely to me too. If you pause the video at 0.08 it looks like the socket on the rail where the injector goes into and the injector are not in line... Any damage on the rail indicating it got pushed sideways while pulling the engine?

Sorry it took so long to get back...

So far as I can tell the rail looks okay. When I removed both rails and brought them over the bench the injectors were all still locked in and I did not notice anything different insofar as play, change in angle, etc between the 2 banks.

I think that you are both right that when I pull the engine the fuel return line being on the wrong side of the e-brake cable on the bank 2 side "pulled" the rail towards the front of the car. I would assume this caused seal to break at the o-rings given the high pressure. When I dis-assembled though I do not see any physical damage.

I guess best-case the act of pulling on the rail allowed pressure to escape, and re-seating with new o-rings, etc would fix.

Worst case - i don't know.. new injectors, replacement of the rail.

Is a logical course of action to finish everything up (I might be at this project for a while), get it all back in the car with new o-rings and see how it goes? It seams that the fuel injectors / rail would be relatively easy to get back to with the engine back in the car?

Here is a pick I took as I removed the injectors on the bank 2 side:

Homeoboxter · 09-17-2021, 01:40 PM

I think it`s much easier to pull the rail now while the engine is on stand than when it`s in the car. So I would pressurize the system somehow and test for leaks before putting the engine back in the car.

ike84 · 09-17-2021, 04:37 PM

Agreed. Event with the air box out it's a bit of a pain. Plus, if you have a leak, is rather have a fire outside the engine bay rather than in it.

Maybe it's just me but did that rail look bent in the middle?

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bg305 · 09-17-2021, 07:59 PM

okay that makes sense.. will research best way to check / pressurize while I have it out.

I do not think it is bent, but I will give it a closer look next time I am down there..

ike84 · 09-18-2021, 05:45 AM

I've not seen it done, but I would run an extension from the supply line to the bank 1 rail, and then just catch the return from bank 2 in a bucket. Then turn the ignition on and jumper the fuel pump relay.

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Steelepuls · 11-13-2023, 02:54 PM

Hello all, been a while since I've been here. I don't want to hijack this thread, but I need help with an injector clip question.

I replaced the AOS hose that starts at the AOS all the way to the far side of the engine (front driver side connection). This project started out just replacing the vacuum lines and vacuum canister. Boy, did this balloon up to a bigger project. In doing so I had to take the intake manifold off and the injector rails.

While reassembling the fuel rail, the #4 injector clip was lost in the engine bay unfortunately. I looked for couple hours with a magnet and flashlight, had no luck. So frustrating.

I ordered the clip to replace it, but my impatience got the best of me, and I could not wait for the part to arrive, so everything was re-assembled, it started up fine, no leaks on the #4 injector, the car ran very smooth. After starting the car, the vibration shook the clip loose and I found it on the ground the next day.

My problem now, is the #4 injector is way too cramp for me to install the clip again, without disassembling the fuel rail again. I need some advice, there is a bolt to hold the fuel rail down, and it is right next to the #4 injector. Does the clip have a critical job or is it just to hold the injector to the rail during disassembly? Should I take the fuel rail apart again? or can I run it for a while without any issues? LMK your thoughts please.

Gilles · 11-13-2023, 03:38 PM

Quote:

Originally Posted by Steelepuls

can I run it for a while without any issues? LMK your thoughts please.

If this was my car, I would definitely Not run the engine with the missing clip on the injector, as once the rail is pressurized it would not take much force to dislodge the injector from the rail and this could cause a large fire very quickly.. (IMHO..)