A4 (B6 Platform) Discussion Discussion forum for the B6 Audi A4 produced from 2002-2005

Resurrected from the dead: High Flow Fuel Rail project (long and lots of pics)

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Old Nov 4, 2007 | 05:26 AM
  #1  
x1rider's Avatar
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Default Resurrected from the dead: High Flow Fuel Rail project (long and lots of pics)

A while ago I tried to put together a high flow fuel rail setup with the ATP fuel rail and failed because I overtightened the fittings at the end of the rail.
The original setup looked like this:
<img src="http://i132.photobucket.com/albums/q33/x1rider/emailfuel1.jpg">
<img src="http://i132.photobucket.com/albums/q33/x1rider/emailinstall1.jpg">
I ordered the replacement fittings but never got around to re-doing it... until now.
I found the original setup was too clunky (I made it up taking measurements with the stock fuel rail in place), so I re-designed it and did it right this time, taking measurements with the high flow rail on the car (I had to rebuild all my fuel lines, re-arrange the fittings, etc...).
Here is what the end of the fuel hard line looks like, pretty straightforward.
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel1.jpg">
Pic of the rail with two injectors for measurements.
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel2.jpg">
Rail in place, ready to re-design the fuel line setup.
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel3.jpg">
This is how I measured the fuel line length, I duct-taped the end of the braided line, marked it where it needed to be cut.
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel4.jpg">
Getting there...
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel5.jpg">
Pic of the new setup at the firewall, as you can see, it's much tighter and cleaner than the original one.
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel6.jpg">
Pic of the overall new design, less clunky than the original one.
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel7.jpg">
Pics of the installed setup (yeah I know, my engine bay is dirty).
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel8.jpg">
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel9.jpg">
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel10.jpg">
Testing time, as you can see, the setup holds the pressure just right (the actual fuel pressure should be 58psi but that gauge consistently reads 2 psi lower, I tested it's accuracy with the two other gauges on my boost leak kit).
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel11.jpg">
To make a long story short, I had to take it off 2 more times, the ATP rail wasn't threaded deep enough and I sprung a leak at both ends. I re-threaded both ends so that I could screw the end fittings in completely.
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel12.jpg">
Unfortunately, I screwed up 2 threads on one of my fittings, discovering that the rail wasn't threaded properly so I have a tiny little leak at one end of the rail.
<img src="http://i132.photobucket.com/albums/q33/x1rider/fuel13.jpg">
Now the stock rail is back on (again) and I'll order another (or maybe five) rail end fitting to finish off this project.
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Old Nov 4, 2007 | 08:22 AM
  #2  
Merkin's Avatar
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can't you just plug one side of the rail like stock ones?
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Old Nov 4, 2007 | 08:32 AM
  #3  
x1rider's Avatar
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Default Yes, I did the dual entry for esthetic reasons only...

I do have the plug but I really wanted to do the 2 line thing.
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