Install Guide for K Series Fuel Rail

Written By: Hybrid Racing
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Introduction

Before getting started we need to set up your fuel rail for with the correct fittings for you fuel lines. This install guide is targeted at installing this fuel rail on a non k-swap vehicle. If you are installing this on a k-swap vehicle, the set up of your fuel rail will be outlined in the fuel line kit you have. Port A: Optional to run a fuel pressure gauge here. If you are not installing a gauge , install the stainless steel NPT plug here. Be sure to place fuel-safe sealant on the threads whether you are running a gauge or the plug.

Port B: -8 to 5/16 quick disconnect union.

Port C: -8 AN plug.

Port D: -8 AN plug.

When set up with the correct fittings, your fuel rail should appear as the one below.

  1. Using a 10 mm socket, remove the two (2) caps nuts holding the cover in place (FIG 1). Once these are removed, pull the cover off. This will take some force. The cover is held on with rubber grommets.

    • Using a 10 mm socket, remove the two (2) caps nuts holding the cover in place (FIG 1). Once these are removed, pull the cover off. This will take some force. The cover is held on with rubber grommets.

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  2. 2A. Unplug all four (4) injector wires from the injectors and using your 10 mm socket again, remove the ground connection from the intake manifold as illustrated in FIG 2A. 2B: Using a flat head screwdriver, unclip the injector harness from the fuel rail as illustrated in FIG 2B. Once both clips are undone, slide the harness off and set it to the side.

    • 2A. Unplug all four (4) injector wires from the injectors and using your 10 mm socket again, remove the ground connection from the intake manifold as illustrated in FIG 2A.

    • 2B: Using a flat head screwdriver, unclip the injector harness from the fuel rail as illustrated in FIG 2B. Once both clips are undone, slide the harness off and set it to the side.

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  3. Remove the cap covering the fuel line connection as shown in FIG 3A.

    • Remove the cap covering the fuel line connection as shown in FIG 3A.

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  4. Place a rag around the fuel line, then squeeze the (2) green tabs and pull the fuel line off as shown in FIG 3B. Be careful when doing so as there will likely be pressure in the fuel line.

    • Place a rag around the fuel line, then squeeze the (2) green tabs and pull the fuel line off as shown in FIG 3B. Be careful when doing so as there will likely be pressure in the fuel line.

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  5. Using a 12mm socket, remove the two (2) nuts holding the fuel rail on and pull the fuel rail off the intake manifold as illustrated in FIG 5. Note: All 4 injectors will likely come out with the fuel rail.

    • Using a 12mm socket, remove the two (2) nuts holding the fuel rail on and pull the fuel rail off the intake manifold as illustrated in FIG 5. Note: All 4 injectors will likely come out with the fuel rail.

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  6. Using a flat-head screwdriver, pull the clips off holding all four (4) injectors in the stock fuel rail as shown in FIG 6. Note: Once you pull one injector out, fuel is going to flow out of the fuel rail. Make sure you have something ready to catch it.

    • Using a flat-head screwdriver, pull the clips off holding all four (4) injectors in the stock fuel rail as shown in FIG 6. Note: Once you pull one injector out, fuel is going to flow out of the fuel rail. Make sure you have something ready to catch it.

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  7. Remove the blue quick disconnect clip from the OEM fuel rail and slide it onto the –8 to 5/16 quick disconnect union as illustrated in FIG 7.

    • Remove the blue quick disconnect clip from the OEM fuel rail and slide it onto the –8 to 5/16 quick disconnect union as illustrated in FIG 7.

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  8. Install the four (4) injectors into your Hybrid Racing fuel rail. Once this is done it should appear as the one in FIG 8. Note: Spread some oil on the O-ring with your finger before installing the injectors to help them slide in without getting cut.

    • Install the four (4) injectors into your Hybrid Racing fuel rail. Once this is done it should appear as the one in FIG 8. Note: Spread some oil on the O-ring with your finger before installing the injectors to help them slide in without getting cut.

    Edit

  9. Line the injectors up with the holes on the intake manifold and press the rail onto the intake manifold. Using a 12 mm socket, install and tighten the two (2) nuts holding the fuel rail on (FIG 9).

    • Line the injectors up with the holes on the intake manifold and press the rail onto the intake manifold. Using a 12 mm socket, install and tighten the two (2) nuts holding the fuel rail on (FIG 9).

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  10. Reconnect the fuel line on the quick disconnect fitting. Do not re-install the cover that you removed in step 3A. (FIG 10)

    • Reconnect the fuel line on the quick disconnect fitting. Do not re-install the cover that you removed in step 3A. (FIG 10)

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  11. Next we need to remove the plastic cover on the injector wiring harness so we can relocate it. Using a flat head, pry each clip apart and remove the cover as shown in FIG 11A and FIG 11B. Next we need to remove the plastic cover on the injector wiring harness so we can relocate it. Using a flat head, pry each clip apart and remove the cover as shown in FIG 11A and FIG 11B.

    • Next we need to remove the plastic cover on the injector wiring harness so we can relocate it. Using a flat head, pry each clip apart and remove the cover as shown in FIG 11A and FIG 11B.

    Edit

  12. Using a 10 mm socket, remove the metal plate the MAP sensor wire is clipped to. Then, with some pliers, squeeze the clip and pull the wire off of the metal plate. (FIG 12A and FIG 12B). Using a 10 mm socket, remove the metal plate the MAP sensor wire is clipped to. Then, with some pliers, squeeze the clip and pull the wire off of the metal plate. (FIG 12A and FIG 12B).

    • Using a 10 mm socket, remove the metal plate the MAP sensor wire is clipped to. Then, with some pliers, squeeze the clip and pull the wire off of the metal plate. (FIG 12A and FIG 12B).

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  13. Plug all four (4) injectors back in. Then, using a 10 mm socket, remove the cap nut on the valve cover. Relocate the injector ground wire to that stud and tighten the cap nut back on top as shown in FIG 13. Note: if the correct wire is not on the corresponding injector the car will not run correctly.

    • Plug all four (4) injectors back in. Then, using a 10 mm socket, remove the cap nut on the valve cover. Relocate the injector ground wire to that stud and tighten the cap nut back on top as shown in FIG 13. Note: if the correct wire is not on the corresponding injector the car will not run correctly.

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  14. Re-install the injector cover that was removed in step 1, or you can leave it off and show off your new Hybrid Racing fuel rail!

    • Re-install the injector cover that was removed in step 1, or you can leave it off and show off your new Hybrid Racing fuel rail!

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Conclusion

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Author

Hybrid Racing

Member since: 04/29/2014

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