Matz
08-04-2006, 10:49 AM
I just finished installing my Helix 720cc fuel injectors. I took some initial pictures before the installation, and also recorded a video during the entire installation.
Overall the process is easy. It took me a little over an hour, but would have taken less if I wasn't trying to talk to the camera and also keeping my son out of trouble in the garage. :)
Parts you'll need:
- 4 fuel injectors (duh)
- 10mm socket
- 12mm socket
- 3/8" drive extension, 3"
- 3/8" ratchet
- needle nose pliers
- jeweler's screwdriver
- philips screwdriver
- paper towels
- latex / rubber gloves (tight fitting)
Optional: (if you lose something or don't want to pry the stock stuff off
- Fuel Injector Insulators MD087060 qty 4 required
- Fuel Injector Sheets MD614805 qty 4 required
- Fuel Injector Orings MD614813 qty 4 required
(thanks, Tam)
General comment: when disconnecting everything, fuel will spill out. I highly recommend using paper towels when possible.
Also, I only took pictures of part of the installation. It would have been too much of a pain to deal with it during the installation...
Video is now available! (http://evo8.initialdproject.com/HowToInstallFuelInjectors/Evo Fuel Injector Installation.mov)
Step 1:
Remove back seat, uncover the fuel pump assembly, and disconnect the power cable.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors1.jpg
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors2.jpg
Step 2:
Start the car to clear out any fuel.
Step 3:
Open the gas cap to relieve any pressure in the system.
Step 4:
Unclamp the fuel line and remove. Keep it pointing up so no fuel spills out.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors3.jpg
Step 5:
Unscrew the (4) 10mm bolts from the fuel rail. You'll want to use your 3" extension as well.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors4.jpg
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors5.jpg
Step 6:
Unscrew the (2) 12mm bolts that hold the fuel rail against the manifold.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors9.jpg
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors8.jpg
Step 7:
Remove the FPR and the fuel return pipes
Step 8:
Pull off the fuel rail, and be sure not to lose the plastic spacers!
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors7.jpg
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors8.jpg
Step 9:
One by one, remove the fuel injectors. Do not lose the insulators! They seal the injectors against the manifold. I recommend that as you remove the injectors, you also pull the insulators and put them in a safe spot. I lost one in my engine bay somewhere.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors6.jpg
Step 10:
One by one, gently remove each injector from the fuel rail. You just need to wiggle from side to side while pullling that they'll come out.
Step 11:
For this step, be careful. You need to remove the metal U clips that hold the wiring in place. Hold your left thumb over the left corner of the U clip. Using your jeweler's flathead screwdriver, pry up from the bottom of the right side of the clip. Once you free it, keep your left thumb in place until you can grab the clip with your needlenose pliers. Pull off the U clip and put it in a safe place. I use a magnetic tray to hold all screws and clips when I work. Repeat this step for all injectors.
Step 12:
Pull off all of the injectors. If you need to reuse the stock o-rings and fuel sheets, go for it. I bought the parts in anticipation of losing some, so I just used new sheets and o-rings. In case you were wondering, the fuel sheets are the rubber gaskets that seal between the injectors and the fuel rail. Put the sheets onto each injector, and then dab some oil on the o-rings to make it easier to put on. What I do to limit the amount of oil I use is get an open quart of oil, flip upside down and right side up, then dab my fingertip against the cap to get just the right amount. Finally, put on the fuel insulators.
Step 13:
One by one, plug the wire harness into each injector and replace the clips. It's easy to do -- just put the left side of the clip over the left side of the injector, and then stretch the right side of the clip over the right side of the injector. It'll help to hold the left side down with your left thumb while doing this. Then just press the clip down and it'll easily snap into place.
Step 14:
One by one, put each injector part of the way into the fuel rail. Then put the other end into the manifold. Gently press down on the fuel rail so that it seats against the fuel injector sheet. You should not have any gap between the rail and sheet. Move on to the next injectors and do the same thing.
Step 15:
Now you can put the fuel rail back on! Grab your plastic spacers and 12mm bolts. The bolt goes through the metal piece first (this is the fuel line), then through the fuel rail, then the spacer, and finally screws into the manifold. Do this on both sides. I found that it's easiest to just get your 12mm socket + extension and start the threading by hand. Make sure all injectors line up with the manifold before tightening the screws!
Step 16:
Plug the FPR and return lines back into the fuel rail and screw in the 10mm bolts. Remember that the short ones go on the FPR side, and the longer ones go on the fuel return side. Hand tighten everything first, then go back and tighten with the ratchet.
Step 17:
Hook up the return line again, and move the clamp back into place.
Step 18:
Plug the fuel pump back in, cover up, and replace your seats.
That's it! It's pretty easy. I started up my car with the ECU+ logging on just to see what would happen, and it idles just fine with a stock map! earlyapex told me just to stay off of WOT, and I will definitely do that until after my CB340 tune tomorrow! :thumbsup:
Video is now available! (http://evo8.initialdproject.com/HowToInstallFuelInjectors/Evo Fuel Injector Installation.mov)
Can a moderator sticky this? I think this is the most thorough how-to yet on fuel injector installation...
Overall the process is easy. It took me a little over an hour, but would have taken less if I wasn't trying to talk to the camera and also keeping my son out of trouble in the garage. :)
Parts you'll need:
- 4 fuel injectors (duh)
- 10mm socket
- 12mm socket
- 3/8" drive extension, 3"
- 3/8" ratchet
- needle nose pliers
- jeweler's screwdriver
- philips screwdriver
- paper towels
- latex / rubber gloves (tight fitting)
Optional: (if you lose something or don't want to pry the stock stuff off
- Fuel Injector Insulators MD087060 qty 4 required
- Fuel Injector Sheets MD614805 qty 4 required
- Fuel Injector Orings MD614813 qty 4 required
(thanks, Tam)
General comment: when disconnecting everything, fuel will spill out. I highly recommend using paper towels when possible.
Also, I only took pictures of part of the installation. It would have been too much of a pain to deal with it during the installation...
Video is now available! (http://evo8.initialdproject.com/HowToInstallFuelInjectors/Evo Fuel Injector Installation.mov)
Step 1:
Remove back seat, uncover the fuel pump assembly, and disconnect the power cable.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors1.jpg
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors2.jpg
Step 2:
Start the car to clear out any fuel.
Step 3:
Open the gas cap to relieve any pressure in the system.
Step 4:
Unclamp the fuel line and remove. Keep it pointing up so no fuel spills out.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors3.jpg
Step 5:
Unscrew the (4) 10mm bolts from the fuel rail. You'll want to use your 3" extension as well.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors4.jpg
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors5.jpg
Step 6:
Unscrew the (2) 12mm bolts that hold the fuel rail against the manifold.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors9.jpg
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors8.jpg
Step 7:
Remove the FPR and the fuel return pipes
Step 8:
Pull off the fuel rail, and be sure not to lose the plastic spacers!
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors7.jpg
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors8.jpg
Step 9:
One by one, remove the fuel injectors. Do not lose the insulators! They seal the injectors against the manifold. I recommend that as you remove the injectors, you also pull the insulators and put them in a safe spot. I lost one in my engine bay somewhere.
http://evo8.initialdproject.com/HowToInstallFuelInjectors/injectors6.jpg
Step 10:
One by one, gently remove each injector from the fuel rail. You just need to wiggle from side to side while pullling that they'll come out.
Step 11:
For this step, be careful. You need to remove the metal U clips that hold the wiring in place. Hold your left thumb over the left corner of the U clip. Using your jeweler's flathead screwdriver, pry up from the bottom of the right side of the clip. Once you free it, keep your left thumb in place until you can grab the clip with your needlenose pliers. Pull off the U clip and put it in a safe place. I use a magnetic tray to hold all screws and clips when I work. Repeat this step for all injectors.
Step 12:
Pull off all of the injectors. If you need to reuse the stock o-rings and fuel sheets, go for it. I bought the parts in anticipation of losing some, so I just used new sheets and o-rings. In case you were wondering, the fuel sheets are the rubber gaskets that seal between the injectors and the fuel rail. Put the sheets onto each injector, and then dab some oil on the o-rings to make it easier to put on. What I do to limit the amount of oil I use is get an open quart of oil, flip upside down and right side up, then dab my fingertip against the cap to get just the right amount. Finally, put on the fuel insulators.
Step 13:
One by one, plug the wire harness into each injector and replace the clips. It's easy to do -- just put the left side of the clip over the left side of the injector, and then stretch the right side of the clip over the right side of the injector. It'll help to hold the left side down with your left thumb while doing this. Then just press the clip down and it'll easily snap into place.
Step 14:
One by one, put each injector part of the way into the fuel rail. Then put the other end into the manifold. Gently press down on the fuel rail so that it seats against the fuel injector sheet. You should not have any gap between the rail and sheet. Move on to the next injectors and do the same thing.
Step 15:
Now you can put the fuel rail back on! Grab your plastic spacers and 12mm bolts. The bolt goes through the metal piece first (this is the fuel line), then through the fuel rail, then the spacer, and finally screws into the manifold. Do this on both sides. I found that it's easiest to just get your 12mm socket + extension and start the threading by hand. Make sure all injectors line up with the manifold before tightening the screws!
Step 16:
Plug the FPR and return lines back into the fuel rail and screw in the 10mm bolts. Remember that the short ones go on the FPR side, and the longer ones go on the fuel return side. Hand tighten everything first, then go back and tighten with the ratchet.
Step 17:
Hook up the return line again, and move the clamp back into place.
Step 18:
Plug the fuel pump back in, cover up, and replace your seats.
That's it! It's pretty easy. I started up my car with the ECU+ logging on just to see what would happen, and it idles just fine with a stock map! earlyapex told me just to stay off of WOT, and I will definitely do that until after my CB340 tune tomorrow! :thumbsup:
Video is now available! (http://evo8.initialdproject.com/HowToInstallFuelInjectors/Evo Fuel Injector Installation.mov)
Can a moderator sticky this? I think this is the most thorough how-to yet on fuel injector installation...