Latest Update:

Removed the old FD

Installed the new one (with the cleaner still in it)

…checked the AFM roller – where the tip of the plunger rests – confirmed it was free to roll – it was a bit stiff – and lubricated the roller and the pivot with Aerokroil.

Connected the FD to the mounted WUR (I originally planned on connecting it to a spare, during the flush, but did not have one of the lines with me)

Connected the Cold Start Valve line to a spare CSV

Connected the empty FD port – first one to be flushed - to a spare Injector Line which was bent to reach a plastic container

Ignition on, AFM FP safety plug off – fuel pump presurizes the system; detected several leaks – turns out the BMW metal brake line fittings did not make a very good seal, although the leakage was relatively minor; lots of shop rags to absorb the seepage

Proceeded to flush the first port (system under pressure, depress AFM plate, eject a few ounces of fuel). Then, proceeded to do the same for the rest of the ports.

As soon as each port was flushed, I installed the mini-filter and then the fuel injector line.

After several cylinders were done, this allowed me to switch the FD port plugs which seeped with the now free ones which did not. Consequently, each successive port took a shorter time to flush, but the difference was 10 seconds instead of 20 (estimated).

Eventually I was done with all eight FD ports, not realizing I was close to ruining the motor…

But first, what emerged from the FD?

In 7 of the ports what emerged was some gasoline along with some dissolved contaminant. The dissolved contaminant was heavier than gasoline and would pool into the corner of the catch container and form a separate somewhat murky glob which would easily break up if shaken, but would congeal again quickly if allowed to settle.

When poured through a paper towel the contaminated residue appeared to be microscopic – I could find no evidence of any debris, however, the contaminant, if allowed to flow through the FD outlet filters and also through the Injector internal filter, could conceivably clog them. Then again, perhaps with enough Techron or B44 or Seafoam in the tank, this sort of contaminant might get dissolved and flushed away completely. Who knows.
One thing is certain, there was some residue in the FD which got dissolved and now ejected.

One of the ports seemed to produce some rusty fuel, but I am not 100% this was not rust from the threads or the old fuel line fitting. There is a possibility that one port has rust inside.

When I was done with all ports and all lines were connected (Injector, WUR, CSV, FD pressure & Return), I went to start the motor.

The starter tried to turn the motor, but the battery seemed weak. The starter would engage, but the motor would not even begin to turn over. I tried a portable booster. Same. I tried the shop charger. Identical response.

Then the hair on the back of my neck stood up.

I ran over to the motor and pulled out all spark plugs. Then I fitted an evacuation canister to the MityVac and slipped the collector tube into the first cylinder whose FD port was flushed. Gave the pump a go and …several ounces of fuel emerged.

Three cylinders had enough gasoline in them to be picked up by the mityvac, with two of them filled up almost completely.

Crestfallen, but still considering myself lucky, I put the tools away and went home.

Tomorrow, the day will start with a fogging oil injection into each of the cylinders, then some cranking, then a spark plug reinstall, then I will see if the motor will run. Stay tuned…

Bostonmish