308 GTSi intake plenum & fuel line removal @ injectors | FerrariChat

308 GTSi intake plenum & fuel line removal @ injectors

Discussion in '308/328' started by F308fan, Feb 27, 2022.

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  1. F308fan

    F308fan Karting

    May 7, 2017
    162
    Peoria, AZ
    Full Name:
    Tony Pacini
    I’m probably making more out of this than necessary, but I want to know what I’m getting into before creating more problems.

    I’m removing the intake plenum to repair a coolant leak. I was able to get all the plenum stud nuts loose except for the 2 middle ones at the front (firewall side). Access is hampered by the fuel lines as they connect to the injectors.

    I can see through the rear glass that the fuel lines curve right in front of the studs/nuts. It seems like disconnecting the lines at those 2 injectors and bending them out of the way would give the access I need.

    Would this be advisable? The injectors were all replaced 2 years ago, so I’d hope that disconnecting them now wouldn’t be too tough. Are they just flare fittings, or are there seals I’d need to replace when removing the lines? Is ‘snug’ good enough, or is there a recommend torque?

    Thanks in advance.
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  2. waymar

    waymar Formula 3

    Sep 2, 2008
    1,354
    Northeast, PA - USA
    Full Name:
    Wayne Martin
    Just be advised there are little spacers where each stud is. They can dislodge and fall down an intake runner.
     
  3. rjlloyd

    rjlloyd Formula Junior

    Jun 19, 2014
    447
    Brisbane, Australia
    Full Name:
    Richard Lloyd
    Injector fittings are just a flare, bat as Wayne says be gentle when lifting the plenum, lift straight up and hopefully the metal spacers will stay in the rubber gaskets
     
    thorn likes this.
  4. thorn

    thorn F1 Rookie
    Silver Subscribed

    Aug 7, 2012
    3,324
    Tallahassee, FL
    Yes, disconnect those fuel lines from the injectors with a flare wrench.
     
  5. F308fan

    F308fan Karting

    May 7, 2017
    162
    Peoria, AZ
    Full Name:
    Tony Pacini
    First of all, mad respect for anyone who does this for a living and/or is proficient at these types of tasks. My hands don’t fit, my eyes can’t see, and most of my tools don’t fit. I can’t imagine how tough a real repair would be on this car.

    I gave up on removing the fuel lines because as I turned the flare nuts the lines started to turn with them. I tried to hold the lines stationary while turning the nuts and they still moved. I ended up just bending the lines slightly to squeeze a wrench in there. Slid cardboard under the gaskets to guard against the metal spacers falling into the intake runners, but the spacers stayed with the gaskets. Endoscope helped me find the 2 washers and 1 nut I dropped in the valley, retrieved with a magnet.

    Next question: do the rubber plenum gaskets need to be replaced? They’re still pliable and appear to be in good condition (flat, no cracks or nicks). While I don’t want to have to pull the plenum off to chase vacuum leaks, I also don’t want to replace the gaskets if not necessary.
     
  6. thorn

    thorn F1 Rookie
    Silver Subscribed

    Aug 7, 2012
    3,324
    Tallahassee, FL
    Did you have a wrench on the line nut and another on the injector, or just the one?
     
  7. F308fan

    F308fan Karting

    May 7, 2017
    162
    Peoria, AZ
    Full Name:
    Tony Pacini
    Only on the line nut. Doh! I didn’t notice the injector nut turning, but I can’t be sure I would have. I’ll have another go at it and hold the injector. Thanks!
     
  8. F308fan

    F308fan Karting

    May 7, 2017
    162
    Peoria, AZ
    Full Name:
    Tony Pacini
    Yes, I’m an idiot.

    The injectors were turning. I was able to secure them with one wrench and loosen the flare fitting with the other. Hopefully I didn’t damage the lines by twisting them.

    Thanks so much for your reply!
     
  9. Ehamilton

    Ehamilton F1 Rookie
    Rossa Subscribed

    Jun 13, 2010
    2,634
    Durham, NC; USA
    Full Name:
    Eric Hamilton
    I've had the plenum off several times over the past few years, always reused that gasket, no problems/leaks. Of course you'll have to use your judgment as to the condition of your gasket but if it is still pliable, smooth, and you're confident that it will compress uniformly without excessive clamping force it'll be good to go.

    First thing you do after lifting the plenum off is put masking tape over the mouths of the intake runners, and removing that tape is the last thing you do before the plenum goes back on.
     
  10. dave80gtsi

    dave80gtsi Formula 3
    Silver Subscribed

    Nov 3, 2003
    1,918
    Ohio
    Full Name:
    Dave Meredith
    But even before this, and prior to the first time lifting off of the plenum, slide 4 pieces of cardboard in between the top of the intake runners and the underside of the plenum.

    This covers the intake runner holes during the removal of the plenum, so to prevent any potential for those small loose cylindrical plenum stud collars to fall into the runner holes.

    DM

    P.S. - Very nice X1/9 forum "Mac" avatar. R.I.P.
     

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