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Dear alfisti,

After doing some work on my Spider (with the help of this great forum!) I sent it off to be tested (MOT). Unfortunately it failed. One major problem was a leaking fuel injector. It would be €1250,- on parts alone! I decided to take it home and try to fix it myself, after I had spoken to the mechanic. It turned out to be one of the short fuel lines connecting the injector to the fuel rail that has become brittle and was leaking if the fuel rail was moved only slightly (which would happen when you are driving it). Elsewhere on this forum I found a thread about a GTV6 with the same problem. It turned out the little lines can be separated (very carefully) from the injectors and can be replaced by high pressure fuel hose and a couple of hose clamps on them. I would expect it to be the same for my Spider, because they are both L-jet and they both use the same Bosch injectors (0280150128) as far as I know. Am I right?
Would a kit like this one Bosch 0280150--- Early V6 6 cylinder Fuel injector hose + clips | eBay get me back on the road? When replacing those hoses, would I need any other parts? I am thinking of rubber seals that break when removing the injectors or something like that.

With kind regards,
Niels
 

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It would be €1250,- on parts alone!
Niels, I have to assume the mechanic was trying to rip you off. That's absolutely crazy. It's just a few hoses and clamps: the only significant cost is the remove/replace labor time.

Anyway, the short hoses from the fuel rail to the injector are easily replaced. You should do all four injectors at the same time, as well as the short hose connecting the injector rail to the hard line at the fuel tank. In fact, this is one of the first things you should do on an old car with injector hoses of unknown age.

They sell kits like the one at the link below. Or you can just buy fuel hose (I believe it's 7.5mm) and proper injector clamps (not worm clamps) and do it that way. The most important thing is not to use a knife on the hoses and nick the hose barbs: I believe Alfa recommends using a soldering iron to carefully cut the hose off.

Alfa Romeo and Fiat Bosch Fuel Injection/Air Hoses

If you do a search here you'll find some good tips. Or take it to another mechanic with more reasonable prices.
 

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Those cost were for 4 completely new Bosch injectors. If I hadn't spoken to the mechanic afterwards I would think he was trying to rip me as well. However I think he honestly didn’t know those fuel lines could be separated from the injectors. He was very kind and made the impression that he knew what he was talking about. He drove the car back on the ramp for me and talked me through each of the MOT failures.
I am going to replace the lines myself. I think I can manage. I managed the rear suspension and anti rollbar bushings already. I am looking for a supplier that’s not located in the US, because that probably means high shipping costs (since I am in the Netherlands).
 

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a set of 4 GP Sorensen injectors from Autozone - a US national auto parts chain is $160.
 

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Those cost were for 4 completely new Bosch injectors. If I hadn't spoken to the mechanic afterwards I would think he was trying to rip me as well. However I think he honestly didn’t know those fuel lines could be separated from the injectors. He was very kind and made the impression that he knew what he was talking about. He drove the car back on the ramp for me and talked me through each of the MOT failures.
I am going to replace the lines myself. I think I can manage. I managed the rear suspension and anti rollbar bushings already. I am looking for a supplier that’s not located in the US, because that probably means high shipping costs (since I am in the Netherlands).
You should be able to get the 7.5 mm high pressure fuel line at any BMW dealer (or other BMW parts supplier), as this is a common fuel line on modern BMWs. For example, BMW part no. 13311469781 should correspond to this fuel line. It is sold by the meter, and one meter should last you a lifetime.
 

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Do be sure you get the proper hose - 7.5mm ID and rated for fuel injection. The commonly available (in the USA) 1/4" is too small & 5/16" is too big.

If you carefully take the old hoses off and save the cup shaped washers (item #3 "bushing") for re-use, you don't need hose clamps. The 7.5mm hose fits tightly and the cup shaped washer prevent the ends from spreading.

Note that the shop manual advises to use a 'welder' (what we'd call a soldering iron) to melt through the hose until it releases its grip. (yes it is safe to use a hot soldering iron - just don't smoke!) This is to avoid nicking the hose barbs as could happen if you use a sharp knife. Such nicks could lead to leaks.

BTW, be sure to slip the cup washer onto the injector & fuel rail before you push the new hose on. Otherwise you'll have to cut off & ruin the new hose. DAMHIK
 

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Niels,
as you mention "MOT", I presumed you were in the UK. Then I read Netherlands!

1250€ for injectors? Wow, I like the Dutch, but your mechanic is just lost when it comes to prices.

Yes, do it yourself, no great problem, in fact take the whole intake off and do it properly, including the 4 intake rubbers...then forget it for the next 10 years!

Anyway, my suggestion: just contact Steve Biggs at Mr. Injector in the UK. Very professional and nice guy.
Contact Us

he serviced (sonic cleaning, new 'aramid' rubber hoses, new pintles, new micro filters, new seals, then flow tested) all my injectors for about 100 pounds sterling, came back like new with a flow report. I sent them to him from Germany, where I am!
You can send him the whole rail to make it easier and he will fit them for you..really not worth just changing one hose..if one leaks, I'll bet next week the others will too!!

(& remember: using the modern 10% bioethanol fuel (E10) they are shoving down our throats in Europe will rot through all your old fuel lines eventually.......stick to super unleaded;))
 

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Sent my entire fuel rail to OKI and for $150.00 I had a new rail with hoses. The rest of the stuff cost ~ 100.00. That's every rubber hose and clamp in the entire car. So $250.00 for parts. Took me ~6 hours to remove change etc. These cars are OLD I stress to all you Alfisti's to change this stuff, at least under the motor. They may look good on the outside, but these fuel lines are BAD!!!! They are OLD!!! For $25.00 at your local Auto Parts store you can get some insurance that a Gas fire will "NOT" kill your Alfa. It's only 3 lines for Spica and Carbs and a fuel rail if Bosch. ~ 6 ft. of fuel line & clamps. Look what happened to one of our members garage!!!!!
 

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Discussion Starter #10
I contacted MR Injector in the UK and ordered an injector revision kit for 41.57 british pounds, inlduing those injector hoses. He was very helpful and friendly. I have revised my injectors and my car is back on the road again.
Thanks for the help again!
 

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I contacted MR Injector in the UK and ordered an injector revision kit for 41.57 british pounds, inlduing those injector hoses. He was very helpful and friendly. I have revised my injectors and my car is back on the road again.
Thanks for the help again!
Great news!

That original estimate was scary!

Happy motoring.

Vin
 

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thanks for posting back a result!

and good to hear Steve from mr.injector was able to help you out.
 

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Niels,
as you mention "MOT", I presumed you were in the UK. Then I read Netherlands!
I thought nobody would know the Dutch equivalent, the APK:wink2:

It turns out the distance between us is "only" about 100 km. I am only a few km from the German border.
 

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You should be able to get the 7.5 mm high pressure fuel line at any BMW dealer (or other BMW parts supplier), as this is a common fuel line on modern BMWs. For example, BMW part no. 13311469781 should correspond to this fuel line. It is sold by the meter, and one meter should last you a lifetime.
Just ordered it via BMW (I have an account w them). They didn't stock it so the parts guy wasn't sure the dimensions. It said 8mm I guess but he didn't know if that was inner or outer diameter.

Guess I'll find out Tuesday, hope I don't have to learn a $32 lesson ha.
 

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Or you could just order the repair kit from a vendor specializing in Alfas:
https://www.centerlinealfa.com/store/1133
I did that the first time. The 12 inches of hose IAP sold me for $40 was stamped "BMW". Next time I bought a meter of the same hose directly from BMW (for around $15 if I recall correctly) and cut out the Alfa "specialist" markup.

I support our vendors, but that was a clear example of gouging with no value added.
 
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