The following steps are typical of most installations:
1. Once the engine has been allowed to cool, disconnect the negative battery cable and relieve fuel system pressure, referring to the appropriate vehicle service manual for the procedure on doing so.
2. Remove the air intake ducting from the throttle body and position it out of the way.
3. Note the location of and remove any vacuum lines connected to the upper intake manifold and position them out of the way.
4. Remove the throttle cable from the throttle body; referring to the appropriate vehicle service manual for the procedure for doing so.
5. Unplug the TPS sensor, which is typically located on top of the throttle body.
6. Remove the nameplate on the top of the upper intake manifold by removing 4 screws.
7. Remove the upper intake manifold bolts (Typically there are 6 of them).
8. 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.
9. Carefully clean the old gasket material from both manifolds, while preventing any debris from entering the intake manifold ports.
10. 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.
11. Disconnect the electrical connector at each injector, making note of the location of each.
12. 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.
13. Remove the vacuum line from the fuel pressure regulator.
14. Remove the bolts that attach the fuel rail to the lower intake (Typically there are 4 of them).
15. 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.
Failure to satisfy all safety considerations will result in fire, explosion, injury and/or loss of life to yourself and/or others.
16. Carefully remove the fuel injectors from the OEM fuel rail.
17. Remove the old o-rings from the fuel injectors, inspect the injectors for any dirt or debris and clean if needed. It is suggested that the old o-rings be replaced, contact your local parts store or dealer to purchase the correct replacement o-rings.
18. Carefully install the new fuel injector o-rings on the injectors
When installing o-rings it is important to place a small amount of light oil on both the o-ring and the mating surface to ease installation and prevent damaging the o-ring.
19. Place a thin coat of light oil in the fuel rail fuel injector bores and in the lower intake manifold injector bores to help prevent cutting the o-rings during installation.
20. 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.
21. Install the fuel rail that has an ORB-08 port plug in one end on the driver side, with the port plug facing the front of the vehicle. This kit comes with 2 aluminum spacers which get installed between the lower intake manifold and the fuel rail brackets. In some instances it will be required to install additional flat washers to space the rail out further from the distributor. After insuring that the injectors are properly seated in the intake manifold injector bores, install the driver side fuel rail mounting bolts, insuring that the fuel rail spacers are captured between the fuel rail bracket and the lower intake manifold.
22. Install the passenger side fuel rail, being careful not to cut any of the o-rings during installation (This fuel rail does not require any spacers between the fuel rail bracket and the lower intake).
23. With the Aeromotive fuel rail properly secured to the intake manifold, Move the fuel injector vertically downward until it bottoms out on the intake manifold, In this downward position, inspect the upper fuel injector o-ring (on the fuel rail side) and insure it is fully covered by the fuel rail injector bore. If any of the o-ring is exposed, loosen the fuel rail bracket screws and adjust the installation height until the oring is no longer exposed and retighten the bracket screws. In the situation where the fuel injector has no vertical travel, either the fuel rail brackets can be adjusted or the brackets shimmed until the fuel injector fits freely. Do not pressurize the fuel rail until the proper fuel rail installation height is achieved.
24. Find suitable place in the vehicle’s engine compartment to mount the Aeromotive regulator, typically on the passenger side inner fender or shock tower. Using the supplied mounting bracket as a template, mark the bracket mounting holes and drill to accept a #10 screw.
25. With the bracket attached to the regulator, mount the bracket and regulator to the vehicle using two #10 screws, nuts and lock washers.
26. Install one ORB-06 o-ring on the cut-off side of each of the three 15606 ORB-06 to AN-06 port fittings.