Install Time: 20-30 minutes
Difficulty level: Not hard
Instructions will be showing the install using fittings a customer may supply themselves to keep costs down. Please note that this method is more difficult and will have more places for possible fuel leaks over using the 90* AN fittings we offer as an alternative add-on to the rail and injector kit.
DO NOT SMOKE WHILE INSTALLING.
CHECK FOR LEAKS!! YOU ARE FULLY RESPONSIBLE FOR YOUR INSTALL
Step 1: Remove air box to expose injectors
Step 2: Prep for fuel to leak when removing old injectors
Step 3: Remove the Old Injectors
Make sure to mark which electrical leads go to which sides and remove your old fuel injectors. Remove injectors and distribution block as you wont be needing any of these converting into the current times with your fuel injection set-up on your Vanagon.
Step 4: Prepping
A. – Install the supplied injectors into the rail while the rail hardware has not been tightened. This will allow some play and make the install easier. The bore on the rail is at a slight angle to retain the OEM angle. After the injectors are in the rail, the rail bracket should be tightened as SHORT as it can get. Once the rail is bolted to the manifold, this will allow the injectors to seat tight. Although “tape” can be used, we highly recommend using Permatex #2 . (Pro Tip: Read the instructions on the Permatex #2 and follow them for best results. You need to let the permatex sit and get tacky before installing or IT WILL LEAK. )
B. – Fittings are 3/8 NPT and will require tape or Permatex to seal properly. If you are not familiar with how or what makes a pipe thread seal, please search the internet for tips on thread taping and tightening. You do not want to over tighten. Doing so can lead to leaks as well as damaging the parts beyond repair.
If using a self supplied 90* option, WAIT to install fittings to rail AFTER Rail has been mounted.
If using the Optional add-on straight AN to NPT fitting , it is easier to thread the straight fitting on while the rail is out, BEFORE the rail is secured to the manifold.
Step 5: Mount fuel rail to manifold
Depending on which fitting route you went, the rail will have either no fittings (a 3/8NPT 90* fittings) or it WILL have the straight 3/8NPT to AN already attached. The rail should be mounted to the manifold by lining the injector up with the intake ports and tightening the bolt to pull rail tight.
Step 6: Install 90* Fittings
A. – In this step, you are going to be taking the 90* fittings that were prepped and/or taped in step 4 and installing them to the correct desired angle. Again, these are NPT threads, so depending on how much tape is used and the angle you desire, you want to be careful. If you go “to far” on your angle, do not back it up. Start over and re-tape your threads.
B. – If you are using the barbed fitting from the add-on kit, you are simply pressing the barb into the fuel line and tightening the hose clamp to secure the fitting. At this time, you can simply attach the female AN fitting to the male fittings already threaded into rail (from before rail was installed). AN fittings are made of aluminum and are very soft. There are special AN wrenches, however, you can use a standard wrench and be careful. Also, AN fittings DO NOT require tape or Permatex, they seal via the 37* angle of the fitting. Taping these threads can cause them to leak. Simply stated; DO NOT use thread sealant on AN fittings.
Repeat on remaining 3 threads.
Step 7: Attach hoses and Check for leaks
We are just buttoning up the job at this point. Connecting all fuel lines and tightening all clamps. Once that is complete, you should be cycling the key on to allow the fuel pump to build pressure. Repeating this several times to ensure lines, rails and injectors have filled and built pressure. Leaks are fairly easy to spot as the tape will become discolored. Address any leaks to ensure a leak free install. For applications with Power Steering, the passenger side may require you to route the IN hose UNDER the sensor cable for an easier install.
Step 8: Finish the install
Reconnect electrical connectors, re-install air box and fire it up! Check again for leaks. You want to really make sure you have no leaks!