Dci Fuel rail help

[rainagain]

Following on from my thread: http://autoshite.com/topic/14378-will-my-bad-luck-ever-end/

 

I came to an agreement with the seller, where he gave me £200 towards a replacement engine, which I now have.

 

It cost me £550 with a 90 day warranty.

 

I'm getting on well with stripping out the original engine

 

 

And it's many many hoses, however I discovered that the fuel rail on the current engine is slightly different from the replacement, the end connector for the leak off piping is different, if you look at my engine below the leak off pipework connects to the fuel rail with a small block connector circled in red:

 

 

The original engine also has small lugs circles in orange which allow a small black plastic cover to attach to the top of the engine. The replacement engine is missing these lugs and the end connector is different, it looks more like the type used to connect to the top of the injectors:

 

 

My problem is I need to use the black plastic leak off pipework off the original engine as the replacement engine has had it's pipework cut. I was thinking about swapping the complete fuel rail over but as the injectors are apparently a pain to remove I need to disconnect the high pressure pipework which according to the Haynes manual you need to replace if it is disturbed. Anyone got any ideas how I can make a working fuel system out of these two?

 

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[panhard65]

The injectors are coded and it would be best to use your original fuel system, but the injectors can be a right bitch to get out. I wouldn't worry too much about the fuel pipes on the 1.9 the injectors on these are a bit more robust than on the 1.5 which will wreck it's injectors just by undoing the pipework. If you can't swap the injectors it's not the end of the world and will run. If you need the spill back pipework from the earlier engine give me a shout as I am breaking a few of these hateful things. Good luck with it

[rainagain]

Thanks for the reply, I take it there is no way to remove the black plastic pipes from the plastic unions on top of the injectors? I thought about maybe pouring boiling water on it to soften the pipe??? 

[panhard65]

To take the pipes off the top of the injector take the clip off and prise out. The pipes don't come off the unions. Boiling water might work though, but as it is all plastic could easily break and they are only available as an assembly.

[dieselnutjob]

 I need to disconnect the high pressure pipework which according to the Haynes manual you need to replace if it is disturbed. 

 

Haynes are being neurotic (actually it's what the manufacturers say).  The advice is the same for Peugeot/Citroen HDIs; I have always ignored it without anything bad happening.

[rainagain]

The injectors are coded and it would be best to use your original fuel system, but the injectors can be a right bitch to get out. I wouldn't worry too much about the fuel pipes on the 1.9 the injectors on these are a bit more robust than on the 1.5 which will wreck it's injectors just by undoing the pipework. If you can't swap the injectors it's not the end of the world and will run. If you need the spill back pipework from the earlier engine give me a shout as I am breaking a few of these hateful things. Good luck with it

 

Which engine is the earlier one, the one with the black plastic on the rail or the one without?

[rainagain]

Haynes are being neurotic (actually it's what the manufacturers say).  The advice is the same for Peugeot/Citroen HDIs; I have always ignored it without anything bad happening.

I think this is what i'm going to do, do you think I would be better undoing the high pressure pipes on the injectors or where they go back to the rail, to allow me to remove the rail?

[panhard65]

The earlier one is the one without the plastic stuff on the rail. The 2nd of your 2 pictures. I would slacken both ends and remove from the rail end if that makes sense

[rainagain]

The earlier one is the one without the plastic stuff on the rail. The 2nd of your 2 pictures. I would slacken both ends and remove from the rail end if that makes sense

 

So i'm replacing my engine with an older one  I also therefore rather doubt the '72,000' miles it apparently has on it.

[panhard65]

I wouldn't worry too much about the age or mileage it's a renault dci they can grenade at any time no matter how well you look after it. I sold one to a mate of mine a few years ago (mistake I know) he has had 2 turbo's and an engine rebuild since. I am sure they will become the Renault 14 of the modern age

[dieselnutjob]

I think this is what i'm going to do, do you think I would be better undoing the high pressure pipes on the injectors or where they go back to the rail, to allow me to remove the rail?

 I would say loosen both ends.

You should reconnect and tighten both ends gradually so that there are no stresses put permanently on the pipe.

If there is any leak on a high pressure side you need to keep your hands away because the pressure is high enough to get diesel through your skin, and that can kill you.

With old style diesels you could loosen a pipe whilst the engine is running to stop a particular piston firing, but doing such a thing on a common rail is probably a bad idea.

Tighten everything up, then start the engine.  If there are any leaks then turn it off and let the pressure drop before you touch it.