Vortech 1999-2000 DOHC VTEC Fuel Rails User Manual
'94-'00 1.6L/1.8L DOHC VTEC HONDA FUEL RAIL
INSTALLATION INSTRUCTIONS
Tools Required:
• 10mm Socket
• Extension
• Ratchet
• 5/32”, 1/4” Hex keys
• 3/4”, 10mm, 22mm Open end wrenches
• Pliers
• Torque wrench
• Blue Loctite 247
BEFORE YOU BEGIN: Some engines originally installed in vehicles
sold/used in Japan may have a different fuel inlet
adapter. Vortech part number 7P563-019 may be
required (applies to engine swaps only).
NOTE: Before beginning installation of the
Maxflow fuel rail, it is imperative to
ensure that the vehicle's engine is cool
to the touch, and that the fuel pressure
has been properly relieved.
1. Disconnect the negative (-) battery cable from the battery
negative terminal.
WARNING: Do not smoke while working on the
fuel system. Keep open flame away
from your work area!
2. Remove the fuel fill cap.
3. Use a box end wrench on the 12mm banjo bolt at the fuel
filter while holding the fuel filter with another wrench. Place
a rag or shop towel over the banjo bolt and slowly loosen one
complete turn.
NOTE: Replace all of the washers whenever the
12mm banjo bolt is loosened.
4. 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.
5. Using a 22mm wrench, remove the fuel pulsation damper
from the end of the fuel rail and set it aside. Remove the fuel
line and all sealing washers.
Note the order of the sealing
washers.
6.
1.6L only:
Disconnect the vacuum line from the evaporative
emission EVAP purge control solenoid valve and the vacuum
line from the purge joint that routes to the evaporative
emission control canister.
7.
1.8L only:
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.
1.6L only:
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 and the EVAP purge
control solenoid to the fuel rail.
P/N:007054
©2000 Vortech Engineering, Inc.
All Rights Reserved. Intl. Copr. Secured
12JUL00 V 1.0
1
8. Disconnect the four injector connectors. Remove, and set
aside, the three retaining nuts (and steel nut spacers on 1.8L
engines) on the back side of the fuel rail that are securing it
to the intake manifold. Remove the fuel rail with injectors.
NOTE: Do not remove the three composite
spacers located beneath the fuel rail
mounting tabs. These are required for
proper Vortech rail spacing.
9. Following the diagram (see
Figure 1
), install the plug and
fuel line/rail adapter onto the fuel rail as shown.
NOTE: The smaller 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.
10. Install the mounting tabs and regulator adapter onto the rail.
1.6L only:
Secure the EVAP purge control solenoid to the
solenoidmounting bracket before mounting it to the rail. A
small amount of blue Loctite 247 is recommended on all
faste ners.
11. Using the factory 6mm bolts, attach the regulator to the
regulator adapter.
12. 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.
NOTE: Make sure that the factory composite rail
spacers are in place on the studs before
installing the rail assembly down onto them.
1.8L only:
13.
mounting studs (positioned on
Slide one of the spacers onto each of the three
top
of the mounting tabs).
Install and properly torque retainer nuts to 12N/m (8.7lb/ft).
1.6L only:
Remove the mounting bracket from the purge
joint and install on the stud closest to the pulsation damper.
Install and properly torque retainer nuts to 12N/m (8.7lb/ft).
Mount the purge joint back onto its mounting bracket.
14. Install the fuel line, sealing washers and pulsation damper in
the original configuration. Torque the pulsation damper to
22N/m (16lb/ft).
15. Connect the vacuum line and fuel hose to the fuel pressure
regulator.
1.6L only:
Connect the vacuum hoses to the
EVAP purge control solenoid valve and purge joint.
16. Torque the banjo bolt on the fuel filter to 33N/m (25 lb/ft) and
reconnect the battery. Check to ensure all fittings are tight
and all hoses are properly routed and connected.
17. 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 specs:
• Mounting tabs and fuel PSI regulator and solenoid:
12N/m (8.7lb/ft)
• Fuel pulsation damper: 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
®
ENGINEERING, INC.
©2000 Vortech Engineering, Inc.
2
All Rights Reserved. Intl. Copr. Secured
P/N:007054
12JUL00 V 1.0
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