DIY:Aem fuel rail installation (R18) - Performance DIY by DIY Guru

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DIY:Aem fuel rail installation (R18)

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-Diy for fuel rail installation on r18 honda,but similar steps can be followed to install fuel rails on other cars as well.
-Read and understand these instructions BEFORE attempting to install this product.
• Do not smoke while working on the fuel system.
• Keep open flames or sparks away from your work area.
• Be sure to relieve fuel pressure while engine is off.

1) Getting started
a) Make sure vehicle is parked on a level surface.
b) Set parking brake.
c) Disconnect the negative cable from the negative battery terminal. (Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio’s preset buttons.)
d) If engine has run within the past two hours let it cool down.
e) Clean area around the fuel rail so that dirt cannot get into the engine.
Note it is recommended to:
• Replace the washer between the service bolt and the special banjo bolt whenever the service bolt is loosened. (where equipped)
• Replace all washers whenever the bolts are removed.
• Replace all cushion rings, seal rings and fuel injector insulators when fuel rail is disassembled.

2) Relieving fuel pressure
a) Remove the two bolts securing the engine cover. (Fig. A)
b) Remove the fuel fill cap.
c) Place a wrench(s) on the fuel pulsation dampener (A) at the fuel rail. Place a rag or shop towel (B) over the fuel pulsation dampener. Slowly loosen the fuel pulsation dampener one complete turn. (Fig. B)
d) When pressure is relieved remove the pulsation dampener.

3) Stock fuel rail and injector removal
a) Remove the bolts securing the engine cover brackets. (Figure A)
b) Disconnect the fuel inlet fitting at the fuel rail. (Figure B)
c) Disconnect the wire connectors from the fuel injectors. Remove the bolt securing the ground strap on the fuel injector wiring harness. Remove the harness holder from the holding tabs. Remove the wiring harness from the harness holder. (Figure C & D)
d) Remove the injector clip from the injectors. (Figure E)
e) Remove the nuts securing the fuel rail to the intake manifold. (Figure F)
f) Remove the fuel rail and injectors from the vehicle. (Figure G)
g) Inspect all seals, o-rings, and washers. If any of these components look at all worn or damaged, then replace with genuine Honda parts.

4) Assembly of the AEM Fuel Rail
a) Remove the old o-rings that are on top of the injectors.
i) Coat the new o-rings supplied with the kit, with clean engine oil.
ii) Install the new o-rings onto the injectors.
b) Insert the o-ring ends of the injectors into the AEM Fuel Rail.
c) Install the fuel rail/injector assembly back onto the vehicle.
i) Be careful to ensure that none of the seals get damaged.
ii) Make sure that all seals and o-rings are properly seated.
d) Install and tighten the fuel rail retainer nuts.
e) Install the two –6 port plugs and –6 crush washers in the ends of the fuel rail. (Figure A)
f) Lubricate the threads of the fuel inlet fitting with a light coat of engine oil. Install the fuel inlet fitting the top, of the AEM Fuel Rail. Make sure that one of the –6 crush washers is installed under the head of the fuel inlet fitting. Be sure that the crush washer is centered under the head of the fuel inlet fitting. (Figure B)
i) Install the fuel inlet banjo line onto the fuel inlet fitting using the aluminum crush washer under the banjo line. (Figure B)
ii) Install the muffler gasket and pulsation dampener onto the fuel inlet fitting to secure the banjo line in place. (Figure B)
g) Plug the fuel inlet banjo line into the factory fuel line. (Figure C)
h) The AEM Fuel Rail comes with two additional fuel ports. If you are running a wet nitrous oxide system, or a fuel pressure gauge, then this port may be used for the additional fuel supply. If you are not in the need of an additional fuel source install the supplied 1/8” NPT plugs. (Figure D)
Note: When installing the tapered plug or any other tapered fitting into the AEM Fuel Rail, use only a lubricant or anti-seize on the threads. Do not under any circumstances use liquid Teflon or Teflon tape as a sealant for any tapered plug or tapered fitting in any fuel system.
i) Install the injector wire harness into the grooved top of the fuel rail.
i) Connect the wire harness to the fuel injectors. (Figure E)
ii) Install the bolt securing the wire harness ground strap to the intake manifold removed in step 3c. (Figure E)
j) Install the fuel rail wire cover over the top of the fuel rail and use the two supplied bolts to secure in place. (Figure F)

5) Finishing Touches
a) Connect the negative battery terminal.
b) Turn the ignition switch to the on position for approximately two seconds. Do not operate the starter. Then turn the ignition switch to the off position.
c) Repeat this procedure three times, and then check all components that were removed during installation for any signs of fuel leakage.
i) Be sure to check the area around the fuel inlet fitting, the –6 plug and the 1/8” NPT plug. If these three items were not installed correctly then they may be prone to leak.
d) If there are signs of leakage you MUST correct the leak before proceeding.
e) If there are no signs of leakage, then start engine and again check for leaks. If there is any sign of leaking you MUST repair the leak before driving the vehicle.

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