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Upgrade: Fuel Injectors, Pt.-1
- Materials:
- In addition to standard automotive-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used here include:
- Mopar Stage-1 kit, including:
- Set of four 527-cc/minute fuel injectors
- Mopar performance power-trained control module
- Vacuum caps
- Deep-well 5 mm socket
- Fire extinguisher
- Shop rags
- Safety goggles
- Note::
- Always wear eye protection and ear protection, and follow proper safety Note, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.
- As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.
- Removing the Fuel Rail
- The new fuel injectors are rated for a flow of 527cc/minute, as compared to 435cc/minute on the stock injectors. The increased flow-rate on the new injectors allows the delivery of more fuel, while maintaining the desired duty-cycle for the injectors at 80 percent or below. The duty cycle is the duration of time that injectors stay open during operation.
- The first step when doing any work on the fuel lines in a fuel-injected car is to relieve the line pressure so the gas doesn't spray everywhere when you open the line. To relieve the fuel pressure, the negative battery cable that was removed for the computer upgrade will have to be reconnected.
- Remove the fuel pump relay from the fuse panel, and then crank the engine. If it starts, let it run until it stalls out. If it doesn't, crank it a few time to make sure all of the remaining fuel pressure is out of the system.
- With the fuel pressure release, reinsert the fuel pump relay.
- Disconnect the negative battery cable once again. The fuel system is now ready for installation of the new injectors.
- Note::
Even though the pressure was released in this fuel system, there's still going to be some spillage when the lines are opened. Be sure to do this job outside or in a well-ventilated area. Stay away from smokers and natural gas appliances -- like water heaters -- that may have a pilot light.
- Remove the fuel rail cover by popping it off.
- The next step is to disconnect the fuel line. Before you do, stuff a rag around the line fitting to absorb any spilled fuel.
- Squeeze the retainer tabs together to release the fitting, and use another rag around the line to catch any spilled fuel.
- Note::
Fuel-soaked rags can spontaneously combust. Keep them outside in an open metal container until they can be disposed of properly.
- The fitting on the fuel rail can be sealed off with a vacuum cap.
- Unplug the mass airflow sensor.
- Pop out the clips that hold the fuel injector harness to the fuel rail with a door panel removal tool.
- The electrical connectors on the injectors themselves have a safety latch. Push the slider back, press the tab, and pull each connector from its injector. A door removal tool can also help where your fingers can't.
- There are two special fuel-rail bolts that hold on the rail cover and attach the rail to the intake manifold. You'll need a deep-well socket to get them out.
- Once everything is free, it's still going to take some effort to pull the fuel rail out. Rock the rail side to side while pulling, and be ready for one or more of the injectors to come unclipped from the rail, spilling the fuel inside. Don't worry if this happens. Just wipe up the spilled fuel and pop out any stubborn injector.
- Set the fuel system components aside and cover the injector holes with a rag to keep anything from falling into the engine.
- Important:
These automotive procedure are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and Note that come with your kit or replacement parts.
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