Flammable Fuel Rails

[bazzbazz]

This topic has been posted in the 932 Series Section, but as it involved a fire and safety issue on many Alfas I thought it best to also post it here as well for maximum viewing -


Over the last year there have been several worrying incidents of Busso powered Alfas (2.5, 3.0 & 3.2) going up in smoke, mostly due to faulty fire rail connections.

A client dropped off his 156 GTA for a cam belt change yesterday and when he arrived I did a customary once over on the car just to make sure there were no nasty surprises that he was unaware of. As soon as he popped the hood I spotted something shiny under the hood, and not the intake pipes.

The primary Fuel Line Connector had slipped back and left a tell tail shiny band on the Fuel Rail Connection Point. This indicates that the connectors grip is losing its integrity and is slipping back and will sooner or later come adrift.



Now of course we can all see that some ham fisted individual has had a go at the connector at sometime and broken the release tags off. Now this may or may not be the cause of the connectors incorrect position, never less, if you ever see anything like this on your busso fuel rails get it fixed/replaced IMMEDIATLY, it could let go today, it could let go next year, but it no doubt will let go.

Is that the sound of many feet running out to the garage for a look see I hear ??   

Baz

[Citroënbender]

It's nice they've left a recessed band on the push coupling so you can safety wire it!

[105gta]

Should also mention that these fittings are prone to cracking due to age,heat and vibration. They usually crack in the corner where they step down to the smallest size.

[poohbah]

Can I just say ... what Bazz said.

No need to ask why ...

[bazzbazz]

I can just imagine poohbah . . . . .

"Ahhh crap . . . . I had just gotten over the nightmares . . . . ."     

[poohbah]

Good therapy

[aggie57]

Good post Bazz. Personally I've had two experiences of under bonnet fuel lines failing on GTV6's. One time the rail on my own car simply popped off the injectors after a rebuild, sprayed fuel all over the engine. Luckily I was test driving without the bonnet on and saw it straight away.

Then just last week when working on my mates car here the flexible line to the regulator had perished with age and started to leak at the joint. Then when we tried to remove it the damned thing broke clean in half. After 32 years the rubber was brittle.

When that happened and with gravity it didn't need the fuel pump to be running, fuel flowed freely out of the broken pipe on to the ground. 

[philpot]

Yes, a salient warning...

For all.

Also, for 33 fuel injected boxer motors, in my case 16V QV, for the many pipes/hoses that sit on top of the hot boxer.  Hidden under the intake plenum, and alarmingly close to the back of the alternator, are rubber hoses coming to and from the pressure regulator.  Unless you take off the plenum, they are unseen and unnoticed until you smell petrol and then decide to lift the bonnet to check why it is not going away... To find a pool of 98 octane sitting on top of the block! 

Oh, Alfa designed and fitted a small plastic shield about the size of a paracetamol packet attached to the base of the plenum placed between the curve of that hose and all those pretty connections at the back of the alternator. ... !

[bonno]

Hi All
Recently replaced the fuel pump on my 2004 156 2.0L JTS and they also have this type of quick connector. Later model Alfas use this type of quick connectors on fuel systems and as such need to be checked routinely or if you smell fuel then you need to track it down and repair ASAP.
cheers
bonno 

[carlo rossi]

with respect gentlemen perhaps this all part of the alfa business '
plan the cars burn around 15 years so you buy another with insurance money
no one gets trade in vals that make you cry and you think yourve done well
NO I had a ROVER ( no not the dog)  once went to the snow and all the the injectors started leaking due to contraction
2 ltrs start leaking from the accelerator pump which are directly above the starter terminals
a p[lastic shield goes along way ( thankyou mr Juicy )
but V engines and flats are the worse as the fuel will pool and off course not evaporate as quick as straights
my alfa sud did this the brass sleeve to the carby FELL OUT yep FELL OUT  #$$%^   #$%^&&
I just finished restoring it first drive
burnt the front end
WEBERS you know they make BBQS as well who would have thought

[Citroënbender]

The brass infeed nipple coming loose, is well known on other makes. It's incinerated Citroën Dee models and Renaults of the same era. There were fixes offered for some carbs with a finely threaded replacement nipple sold in a kit with tap to suit.

[ACE]

Bazz et al,
There is what looks like a locking ring that fits in the recessed groove at the end of these connectors (both missing in this photo).
Are they available separately?

[bazzbazz]

I see the groove you mention, no locking ring fits there.

[ACE]

See attached.
The upper connector (white) has an extra black bit (locking ring?)
But the lower one does not :-(

[bazzbazz]

Sorry, I misunderstood what you meant.

The part you are referring to simply prevents one from pressing the release horns on the side. It does nothing to help hold the fitting in place or prevent its migration from age/wear.

In fact, if you look closely you will see that BOTH have migrated back along the spigot, see the band of slightly brighter materiel.

But well done on pointing it out, will no doubt save some confusion by those following this thread.