Assembly - Injectors/Intake Plenum

1. Lay out both new fuel rails and new hardware supplied with this campaign. Note the new spring type clamps.









*2. On top-feed injectors, and on later bottom feed kits, tape the spacers in place on the injector holders with masking tape. The spacers are pre-applied on early bottom-feed injector kits.

3. Using a clean, fiber free applicator, such as a plastic coffee stirrer, lubricate the inside of all of the fuel hoses with a small amount of the Daikin CTFE oil that is provided with this campaign. DO NOT use cotton swabs or similar type applicators.

NOTE:
DO NOT use any type of cleaning solvents on the hoses supplied in the kit.

DO NOT use any oil/lubricant other than the Daikin CTFE oil supplied in this campaign. Other oils/lubricants can react with the pre-applied adhesive on these replacement hoses.

*4. Lubricate the inside and outside of the lower injector insulators with the Daikin CTFE oil and insert the insulators into the intake manifold.

5. Install the sub-hose to the sub-tube and install the sub-tube. Tighten the fuel rail bolts to 13 to 16 ft. lbs. (18 - 28 Nm).

*NOTE:
Before installing the fuel rail assemblies, check all injector tips for damage.

6. Install the fuel rail assemblies. Set the assembly over the intake manifold and connect each fuel rail to the fuel regulator. Connect the crossover hose.

7. Lower the injectors into the injector insulators in the manifold and install the holder bolts. Torque the injector holder bolts to 22 to 28 in. lbs. (2.5 - 3.2 Nm).

8. Position the clamps on the sub-tube, crossover tube, and the fuel regulator hoses. Make sure the fuel tubes and hoses are in proper alignment. If a hose is stressed, it can cause a leak.

9. Replace the fuel inlet hose. Tighten the hose clamps by hand. The clamp is properly tightened when a dime will just fit into the gap.









NOTE:
An over tightened clamp may damage the hose and cause a fuel leak.

10. Install the fuel rail bracket bolts and torque to 13 - 16 ft. lbs. (18 - 28 Nm).

*11. Inspect the injector connectors for damage. If any type of damage is found such as broken connectors, corroded terminals, pins pushed in or bent, install the sub-harness kit using the Sub-harness Procedure. If the injector subharness(es) do not need to be replaced, continue with this procedure.

12. Attach the injector connectors to the fuel injectors.

13. Blow all dirt and dust from the intake manifold, then remove the plastic intake manifold plugs. Be sure to wear protective goggles and respirator when removing dirt and dust.

14. Brush a small amount of Permatex High Tack Adhesive Sealant P/N 98H on the intake manifold and set the gasket in place.

15. Remove the plastic intake plugs from the plenum. Lower the plenum over the engine, align the air duct with the air intake, and rotate the plenum into place on the manifold. Be sure the air duct and wiring harness are not damaged during installation.

16. Install the intake manifold bolts, and torque them to 13 - 16 ft. lbs. (18 - 22 Nm).

17. Install the air duct and tighten clamps.