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'96-'00 1.6L SOHC VTEC HONDA FUEL RAIL
INSTALLATION INSTRUCTIONS
Tools required:
• Metric socket set and ratchet (extension optional)
• 5/32", 1/4" Hex keys
• 3/4", 10mm, 17mm open end wrenches
• Pliers
• Torque wrench
• Blue Loctite 247
NOTE: BEFORE BEGINNING INSTALLATION OF THE MAXFLOW POWER
RAIL, IT IS IMPERATIVE TO ENSURE THAT THE VEHICLE'S
ENGINE IS COOL TO THE TOUCH, AND THE FUEL PRESSURE
HAS BEEN PROPERLY RELIEVED.
1. Disconnect the negative (-) battery cable from the battery
negative terminal.
2. Remove the fuel fill cap.
3. Using a 10mm socket and ratchet, remove the two bolts
on top of the stock fuel rail securing the injector wiring
harness. Remove the plastic harness from injector wiring
loom.
4. Remove the sealing nut from the end of the fuel rail, and
set aside.
NOTE: Place a rag or shop towel over the nut
and slowly loosen.
Remove the fuel line and all sealing washers.
Note the
installation order of the sealing washers.
5. Disconnect the vacuum signal line from the top of the fuel
regulator. Using a 10mm socket and ratchet, remove the
bolts holding the fuel regulator to the fuel rail.
6. Disconnect the fuel injector connectors. Remove, and set
aside, the retaining nuts on the backside of the fuel rail
that are securing it to the intake manifold. Remove the
fuel rail and injectors.
7. Following the diagram (see
Figure 1
fuel line/rail adapter onto the fuel rail as shown.
), install the plug and
Note that
the smallest of the three O-rings is to be used for the
regulator adapter.
Use a small amount of clean engine oil
to lubricate the O-rings before installation.
8. Install the mounting tabs and regulator adapter onto the
fuel rail using the supplied fasteners. A small amount of
Blue Loctite 247 is recommended on all fasteners.
9. Using the factory 6mm bolts, attach the regulator to the
regulator adapter.
10. Lubricate the injector O-rings and seal rings (on the
intake manifold) with clean engine oil. To prevent damage to the O-rings, install the injectors in the fuel rail first,
then install the rail assembly into the intake manifold.
11. Install and properly torque retainer nuts to 12N/m (8.7lb/ft).
P/N:007053
©2000 Vortech Engineering, Inc.
All Rights Reserved. Intl. Copr. Secured
12JUL00 V 1.0
1
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12. Install the fuel line, sealing washers and nut in the original
configuration and torque to 22N/m (16lb/ft).
13. Connect the vacuum line and fuel hose to the fuel
pressure regulator. Reconnect the battery and check to
ensure all fittings are tight and all hoses are properly
routed and connected.
14. Turn the ignition switch on, but do not operate the starter.
After the fuel pump has run for approximately two seconds, the fuel pressure in the fuel line will rise. Repeat this
two or three times, then check for any possible fuel leaks.
Torque specifications:
• Mounting tabs and fuel pressure regulator - 12N/m
(8.7lb/ft)
• Banjo sealing nut - 22N/m (16lb/ft)
1650 PACIFIC AVENUE • CHANNEL ISLANDS, CA 93033-9901 • (805) 247-0226
FAX (805) 247-0669 • www.vortechsuperchargers.com • M-F 8:00 AM - 4:30 PM PST
P/N:007053
©2000 Vortech Engineering, Inc.
All Rights Reserved. Intl. Copr. Secured
12JUL00 V 1.0
®
ENGINEERING, INC.
2
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P/N:007053
©2000 Vortech Engineering, Inc.
All Rights Reserved. Intl. Copr. Secured
12JUL00 V 1.0
HONDA FUEL RAIL ASSEMBLY DIAGRAM
('96-'00 1.6 SOHC VTEC)
EVAPORATIVE EMISSION PURGE
CONTROL SOLENOID VALVE
SOLENOID
MOUNTING
BRACKET
6mm
NYLOCK NUT
6mm WASHER
10-24 x 3/8” SHCS
#10 WASHER
10-24 x 1/2” SHCS
REGULATOR
ADAPTER
3
O-RING
FUEL RAIL
ADAPTER
PLUG
-6 O-RING
FACTORY
6mm BOLT
FUEL RAIL
10-24 x 3/8” SHCS
MOUNTING TAB
Figure 1
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