Section 2 – Fuel Rail Installation
Note:
Please note, due to the wide range of applications and varying OEM and after market component tolerances it has
been found in a few isolated cases it is necessary to install a 3/8” thick spacer between the upper and lower intake
manifolds. This will allow you to gain clearance between the top of the fuel rails and the bottom of the upper intake
manifold. These spacers are readily available from your local speed shop or mail order warehouse.
2-1. Remove the air intake ducting from the throttle body and position it out of the way.
2-2. Note the location of and remove any vacuum lines connected to the upper intake manifold and position them out of
the way.
2-3. Remove the throttle cable from the throttle body; referring to the appropriate vehicle service manual for the procedure
for doing so.
2-4. Unplug the TPS sensor, which is typically located on top of the throttle body.
2-5. Remove the nameplate on the top of the upper intake manifold by removing 4 screws.
2-6. Remove the upper intake manifold bolts (Typically there are 6 of them).
2-7. Gently remove the upper intake from the engine. Place clean shop towels into or tape up the lower intake ports to
prevent any material from entering the intake.
2-8. Carefully clean the old gasket material from both manifolds, while preventing any debris from entering the intake
manifold ports.
2-9. Check for any dirt or debris around the fuel injectors. If any is evident, wash it off with some solvent parts cleaner or
wipe it off with a clean shop towel.
2-10. Disconnect the electrical connector at each injector, making note of the location of each.
2-11. Disconnect both the supply and return fuel lines from the OEM fuel rails. These lines are attached by a special
quick disconnect fitting which requires a special tool for removal. Place clean shop towels around the open fuel
lines to catch any gasoline that may drip out and to prevent any dirt from entering the fuel lines.
2-12. Remove the vacuum line from the fuel pressure regulator.
2-13. Remove the bolts that attach the fuel rail to the lower intake (Typically there are 4 of them).
2-14. Place clean shop towels around the injectors to catch any gasoline that may be spilled during their removal.
Remove the injectors from the manifold by gently pulling upward on the fuel rail / injector assembly. Keep all
injectors connected to the fuel rails. If an injector does pull out of the fuel rail, it may spill a large amount of fuel.
2-15. Carefully remove the fuel injectors from the fuel rail.
2-16. Inspect the injector o-rings for any sign of damage or cracking. Replace o-rings, if necessary, with OEM
replacement parts available from most auto parts stores.
2-17. Carefully install the new fuel injector o-rings on the injectors.
2-18. Place a thin coat of light oil or petroleum jelly in the fuel rail fuel injector bores and in the lower intake manifold
injector bores to help prevent cutting the o-rings during installation.
2-19. Carefully place the fuel injectors in the fuel rails. Position the electrical connector on each fuel injector to the
opposite side of the fuel rail as the mounting bracket.
