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Fuel Rail Leak 200

posted by  RepairmanJackal on  Sat Jan 30 10:58 CST 2010
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last visit: Tue Jun 10 09:52 CST 2014
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This just goes bad to worse. I must have aggravated a borderline problem when I was testing for fuel pressure at the rail. I've got no idea how I could have caused this problem, but I never noticed a leak before a few days ago.

There appear to be two tiny pinhole leaks in the tail-end of my fuel rail. The holes let loose two a tiny little jets of fuel - almost atomized - right on top of my #4 intake. That's a sure recipe for fun! :(

So I pulled it, expecting to change it out with a spare from a 740. I realized, that despite the fact that they are nearly identical, the 240 rail has a fitting right next to the #4 injector, the 740 rail does not. Without that critical fitting, I can't swap these parts.

Figures. When I was repairing replacing the busted interior on this 1990 model, I couldn't find anything within 3 years of my model. How variable are these parts on the B230F engines? I know an 86 740's rail is different, what about an 87 240?

It is too late to head to the PnP yards today, but I'll head out tomorrow looking for a match. Can anyone give me advice on the interchange? From what I've found so far, I can't use a pre-1989 type. Would a later 740 or 940 rail work?

I considered soldering the holes shut, but the pinhole leaks are behind the #4 injector, below the intake line fitting. It is very weird that they are not at any of the seams - just right in the middle of the sidewall behind the fitting.

A replacement would be the safest solution, but has anyone ever soldered holes like that shut?







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    Fuel Rail Leak 200

    uid 27's pic
    posted by  Art Benstein on  Sun Jan 31 05:48 CST 2010
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    last visit: Fri Oct 17 20:10 CST 2014
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    The extra port you find is for the cold start injector. You can do without it. In fact, if you do what we all suggest on this board and replace your failure-prone -561 fuel computer with the -951 version, cold start is cared for by the service injectors.

    Edit: Oh, I forgot you're selling it.

    Addressing your question, I've never seen, nor heard of, pinholes in the rail. The only leaking rails seem to be those in the 900's (or maybe 700's) with Regina fuel, where the end cap (opposite end mind you) isn't sealed well. And that would be a seam, not a pinhole in the wall of drawn metal. I agree, you should replace it and not solder it. Then peel it apart and try to tell us all what happened.

    Speaking of "what happened", what became of the non-operating ignition?

    No OBD on #6
    --
    Art Benstein near Baltimore

    "Freedom is not worth having if it does not include the freedom to make mistakes."
    -Mahatma Gandhi








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      Fuel Rail Leak 200

      posted by  someone claiming to be Jack on  Sun Jan 31 08:17 CST 2010 [RELATED]

      Well, after calling around the local junkyards, I've determined that I can't replace the rail locally (today). I removed it, soldered it and replaced it.

      The solder reduced the leakage from two high-pressure streams to a slow "seep" That at least minimized the chance of fire before I can work out a replacement.

      I suspected that the extra fitting was for a cold-start injector, but I thought that tech approach went away with the end of the D/K-jet cars.

      The no start went away the next day - again defying proper diagnosis. I went ahead and performed the partial tune-up and cleaned the FI fuse (which was not corroded but had been laying under the power steering reservoir). I still went ahead and ordered the IPD waterproof fuse kit, a new CPS and some new injector seals.

      Today, I cleaned the engine compartment with a lot of soapy water and brake cleaner. Despite the wetness, the car started and ran at all points of the cleaning process. I tugged and twisted the cps wiring - which has lost it's insulation down to the bellhousing, but could cause no stumble, stall, or poor running during the whole process.

      I worry that I'm chasing the wrong rabbit, but I doubt I can sell the car w/o at least replacing the prime suspect (CPS).

      I got some photos of the rail, so I can hopefully turn one up soon. I'm planning on buying a c70 this week and need to get this 240 out of my life soon.








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    Fuel Rail Leak 200

    posted by  trichard on  Sat Jan 30 12:16 CST 2010
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    last visit: Fri Oct 24 05:52 CST 2014
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    email me a picture or post one here. i have a dozen rails from 240's, 940's and 760's. maybe i have one which works.








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      Fuel Rail Leak 200

      posted by  RepairmanJackal on  Sat Jan 30 12:47 CST 2010
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      last visit: Tue Jun 10 09:52 CST 2014
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      I've had a chance to check my 1995 940 and found that the 940 also looks identical, but lacks the all-too-important rear fuel fitting. I think I can only use a 1989-1992 rail from a 240.

      It's too dark out to photograph, but I'll try and post tomorrow if I can't find anything at the local PnPs.







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