AEM 25-112BK High Volume Fuel Rail - Manual (Page 3)

3) Stock fuel rail, injectors and fuel pressure regulator removal
a) Disconnect the fuel inlet fitting at the fuel rail.
i) Be careful not to loose either of the two crush washers.
b) Disconnect the wire connectors from the fuel injectors.
c) Disconnect the vacuum hose from the fuel pressure regulator.
d) Place a rag or shop towel over the fuel pressure regulator.
i) Remove the two 6mm retaining bolts.
ii) Position the fuel pressure regulator out of the way.
(1) Be careful not to loose the o-ring that goes between the fuel rail and the fuel pressure regulator.
e) Loosen and remove the retainer nuts/bolts on the fuel rail, injector harness, and any other components
that may be bolted to the fuel rail.
f) Disconnect the fuel rail.
g) Remove the fuel injectors from the intake manifold.
i) Some models have an injector insulator on the injector tip (the end of the injector that goes into the
intake manifold) and some models do not. Note the arrangement your model has and be sure to
reassemble the injector assembly correctly.
h) 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) Line up the stock fuel rail with the AEM Fuel Rail.
i) Lubricate the threads of the fuel inlet fitting with a light coat of engine oil. Install the fuel inlet fitting
into the end, or the top, of the AEM Fuel Rail that matches the placement of the fitting in the stock
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.
a) The AEM Fuel Rail comes with an additional fuel port. 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 plug. (Fig. 5)
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.
b) 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.
c) Insert the o-ring ends of the injectors into the AEM Fuel Rail.
d) Coat the seal rings with clean engine oil and then install them into the intake manifold.
e) Install the fuel rail/injector assembly back onto the vehicle.
i) Be careful to insure that none of the seals get damaged.
ii) Make sure that all seals and o-rings are properly seated.
f) Install and tighten the fuel rail retainer nuts.
g) Install the fuel pressure regulator onto the AEM Fuel Rail. Make sure that the o-ring is properly
installed between the regulator and the fuel rail . Note: If you are running the stock Honda
fuel pressure regulator, DO NOT install the additional 1/8” NPT plug into the fuel
return hole. (#2 in Fig.3) On all applications, the fuel return hole will be located
between the two threaded regulator mounting holes (#1 in Fig. 3)
h) Connect the vacuum hose to the top of the fuel pressure regulator.
i) Some kits require the replacement of this hose with a longer one. If your kit requires this then
replace the original vacuum hose with the one that is supplied in the kit.
i) Install the injector wire harness and related brackets, if equipped.
j) Install the fuel supply line to the AEM Fuel Rail.
i)
Be sure that a crush washer is positioned on both sides of the banjo fitting.
ii) Torque the retaining nut to 12 lbf.-ft. D O NOT OVER TIGHTEN .
iii) Make sure the plug on the end of the fuel rail is tight.
k) Install any remaining components that were removed during disassembly.