OK, I am in the middle of my turbo setup and have run into a catastrophic problem. I have the HAHN STAGE 2 kit for my 2002 cavalier ecotec. My problem is this:
I installed the new high flow fuel injectors. these require you to put new connections onto the harness which plug into the injectors with the new clips. However, it is literally impossible to get the new plugs to clip into the injectors because that plastic manifold thing is in the way! like literally no room to get the plugs on there.. so has anyone else ran into this problem and have a fix for it!!! please help me you guys i am trying to get this install done this weekend..
<img src="http://www.j-body.org/registry/cav13/Chris-Cav-004.jpg">
Do you have a picture you can post up? I'm not sure I undertand what you're saying.
dude if thats catastrophic you may have many issues in the future. Anywho take the two ten mm bolts out of the fuel rail hold down take out the injectors and plug them in when they are out if its that much of a problem. But there should be ample room to do such a task. But hey im not in front of the car. Good luck
*2012 mazdaspeed3*
sorry i do not have pictures at the time. I am not sure if i can explain it clearer. the hahn stage 2 uses new injectors, however they require you to solder new plugs onto the harness so that you can plug it into the new injectors, but the way the new plugs are designed, you cannot physically plugs the 4 harness plugs into the injectors because the black plastic manifold is in the way. Its absolutely retarded. so i mean someone else must have ran into this problem..
<img src="http://www.j-body.org/registry/cav13/Chris-Cav-004.jpg">
I'm sorry I can't be much help.
But since you're on a short time table, I would go ahead and skip this step for now if you can, and move on. Somebody will post up with some good information if Respooled2k3 didnt help you out.
if you take the fuel rail out and do it you should have no problem
*2012 mazdaspeed3*
I have taken the fuel rail out but when everything new part provided is put on you can not put the fuel rail back on because the new fuel injectors plugs and pins are hitting the air intake under the throttle body.
<img src="http://www.j-body.org/registry/cav13/Chris-Cav-004.jpg">
Your doing something wrong. Plain and simple. The injectors fit right in as they say in the directions. The manifold cannot get it the way....it is physically impossible for it to considering the holes are notched out of the manifold too.
I used to race cars, now I race myself.
5K PB: 24:50
10K PB: 54:26
OK, is it possible that they had sent me the wrong injectors? because the size of the clips that plug into the injectors are so big that they cannot pass the plastic manifold. also, my factory plastic manifold does not have any notching in it...
<img src="http://www.j-body.org/registry/cav13/Chris-Cav-004.jpg">
also, the injectors that i got with the kit do slide perfectly into the into the fuel rail as well as the engine, however, again the wire harness clip that is supposed to plug into the injector cannot pass the factory manifold directly under the injectors.
<img src="http://www.j-body.org/registry/cav13/Chris-Cav-004.jpg">
Bingo....you need the 03 rail. Did you tell them the kit was for an 02?
I used to race cars, now I race myself.
5K PB: 24:50
10K PB: 54:26
yes, i made super clear to them that it was for a 2002. so did they send me the wrong injectors for my car?
<img src="http://www.j-body.org/registry/cav13/Chris-Cav-004.jpg">
also, i do not see how a new fuel rail would solve my problems, the injector sits in the rail perfectly, and the injector sits into the engine perfectly. the problem is that once the injectors are in the engine, you cannot plug the wire harness into the injectors... simply because of the fact that the new big square connectors you have to solder to the harness are to big to go around the injector plug because of the goofy plastic of the manifold. if you look at the stock injector above, you see its much smaller so the connector fit over the plug without interfering with the manifold..
<img src="http://www.j-body.org/registry/cav13/Chris-Cav-004.jpg">
you need to take a pic of the manifold with the injectors in it and show us where the plug "doesnt fit". If anything im sure you can rip the intake mani off along with the tb and plug everything in then assemble again.
*2012 mazdaspeed3*
ok, well i will be going to the garage later today so i will take numerous pictures of excatly the problem. but i mean how is it possible no one with a 2002 ecotec with hahn stage 2 havent had this problem? my only thought is that they send the wrong injectors.. but i will have pics for you guys today
<img src="http://www.j-body.org/registry/cav13/Chris-Cav-004.jpg">
they send you the one for 03 in the 02 kit comes with some spacers
say that again please?
<img src="http://www.j-body.org/registry/cav13/Chris-Cav-004.jpg">
the 02 from the factory uses different fuel rail and injectors than the 03+
because of this the 03+ comes with spacers that go into the head before the injector, which is why you having an 02 is a problem... the spacers would kick those out so you wouldnt have that problem
** FOR SALE**
http://www.j-body.org/forums/read.php?f=24&i=110879&t=110879
ok, does anyone have a pic of these spacers? do the spacers go like under the fuel injector?
