fr-s / brz / gt86 fuel rail kit - racer x fabrication · 21.install fuel rail dampers, be sure to...

FR-S / BRZ / GT86 Fuel Rail Kit Install Time: 1 - 2 hours

In the Box: • (2) Fuel rails • (4) Mounting brackets • (8) M5 SS allen head bolts and washers • (3) 6AN to 8AN fittings • (1) 8AN plug • (2) Fuel rail damper fittings • (2) AN fuel lines and fittings (Pre-assembled) • (1) Injector driver ECU mounting bracket • (2) M6 bolts

Tools: • 10mm socket, shallow and deep well • 12mm socket, deep well • Socket driver • Socket extension • Torque wrench • Flat head screwdriver • Stubby philips screwdriver • 12mm wrench • 11/16” wrench • 3/4” wrench • 7/8” wrench • 22mm wrench

Optional: • Magnetic LED light • Pliers • Cotter pin puller • 12mm Crows foot

Instructions: 1. Remove OEM intake elbow, and sound tube. Use 5/16 socket to loosen clamps at sound tube. Remove sound

tube from engine bay after clamps are loosened. (Fig 1) 2. Use 10mm socket to remove (2) bolts from Sound Generator assembly. (The fuel rail kit is not compatible with

the sound generator assembly) (Fig 2 & 3) 3. In the engine bay gently remove the tube from the cabin. Cut this plastic zip tie holding the tube (by battery).

Remove plastic zip tie held at bracket. Remove tube from engine bay. (Fig 4)

© 2016 Racer X Fabrication

4. Using a flat head screwdriver, gently push in on the wire tabs to release them from the injector driver mounting bracket. (Fig 5 & 6)

5. Here is the wiring clip removed from the mounting bracket. The plastic clips can be removed permanently, as they will not be used with the fuel rail kit. (Fig 7)

6. Remove the (3) mounting bolts for the injector driver ECU using a 10mm socket. Move the injector driver ECU away from the mounting bracket. Tip: The last bolt is below the injector driver ECU. (Fig 8 & 9)

7. Unclip the wiring harness from the mounting bracket. Remove (2) bolts using 12mm socket. Tip: Long socket extension helps to reach bolt by wiring harness. (Fig 10 & 11)

8. Remove injector driver mounting bracket from engine bay. (Fig 12) 9. Here is the OEM fuel rail, below the mounting bracket. Remove (2) bolts for the bottom bracket using 10mm

socket. (Fig 13) 10.Now we will move to the left side of vehicle. Remove (2) bolts using 12mm socket. (Fig 14 & 15) 11.Remove bolt holding OEM fuel line (10mm socket). Unbolt OEM fuel line clip (10mm socket). Tip: Unbolting

these two pieces will allow some flexibility in the fuel lines to remove the injector cover. (Fig 16 & 17) 12.Remove the oil filter and oil cap for clearance to remove injector cover. Injector cover removed from engine

bay. (Fig 18 & 19) 13.Moving back to the right side of vehicle, find the OEM fuel line connection point to OEM rail. Squeeze blue clip

to release line, a flat head screwdriver helps to disengage clip completely (DO NOT REMOVE YET). Tip: Use a rag or container to eliminate fuel spill in engine bay. Unclip injector electrical connectors from both injectors. (Fig 20 & 21)

14.Remove (2) bolts from OEM fuel rail using 12mm socket. Gently remove OEM fuel line from rail, apply pressure away from rail to disengage clip. Remove fuel rail from intake manifold. Tip: Fuel will spill from fuel rail and OEM fuel line. (Fig 22)

15.Move back to the left side of vehicle to remove the remaining fuel rail. Locate OEM fuel line, unclip electrical connector at high pressure fuel pump. Repeat steps above to remove rail. Tip: Again use a rag or container to eliminate fuel spill in engine bay. (Fig 23 & 24)

16.To completely remove rail, unscrew clamp using short philips screwdriver that holds OEM fuel line. Gently pry off OEM line from metal line to remove fuel rail. (Fig 25)

17.OEM fuel rails removed from engine bay. (Fig 26) 18.Finally remove fuel crossover line from engine bay. Tip: The crossover line is attached at (3) points on the

intake manifold. One on each side of the manifold and then directly behind the throttle body. (Fig 27 & 28) 19.Remove OEM fuel injectors from rail. Hold fuel rail in vise, use 22mm open wrench to remove fuel rail damper

(for both rails). Keep washers with fuel rail dampers to be used with new fuel rails. (Fig 29 & 30) 20.Assembly new fuel rails. Install mounting brackets with (4) allen head bolts / lock washers for each rail using

4mm allen wrench. Lubricate all o rings for the AN fittings (O ring could tear with out lubrication). Install AN fittings using 7/8 open end wrench, and 3/4 open end wrench. (Fig 31 & 32)

21.Install fuel rail dampers, be sure to center washers on fuel rail fitting. Then tighten fuel rail damper to new fuel rails. Install fuel injectors, but do not completely seat to rail. (Fig 33 & 34)

22.Install right side fuel rail. Plug electrical connectors into injectors. Seat injectors to fuel rail, be sure that connectors are guided on to fuel injector alignment tabs. Tip: Fuel injector can be removed from rail, then plug connector to injector before installing. (Fig 35)

23.Guide injectors into intake manifold, using OEM bolts, bolt fuel rail to intake manifold. Torque (2) bolts to 14 ft/lbs using 12mm socket. Tip: Bolt closest to firewall (RH side) will be difficult to access, a 12mm crows foot or open ended wrench will help. (Fig 36 & 37)

24.Repeat above steps to install LH side rail. Plug electrical connector into OEM high pressure fuel pump. Tip: Bolt closest to front of vehicle will be difficult to access, a 12mm crows foot or open ended wrench will help. (Fig 38 & 39)

25.Install New AN fuel lines. Thread fittings onto right and left fuel rail, tighten using 11/16” open end wrench. Keep rail in place while tightening, using 7/8” open end wrench on rail fitting. Tip: AN fittings seal on the face, do not over tighten fittings. Right side, uses 45 degree AN fitting. Left side, uses 90 degree AN fitting. (Fig 40 & 41)

26.Install new AN fuel supply line. Thread fitting onto front left side of fuel rail, tighten using 11/16” open end wrench. Keep rail in place while tightening using 7/8” open end wrench on rail fitting. Tip: AN fittings seal on the face, do not over tighten fittings. Finally, install OEM fuel line. Route through OEM line clip and guide onto metal supply line. Slide OEM clamp onto AN line and tighten using philips screwdriver. (Fig 42 & 43)

27.Install new injector driver ECU bracket. (Fig 44)


28.Install (2) supplied bolts using 10mm socket, do not tighten. Install bolt to front of bracket using 12mm socket, torque to 14 ft/lbs. Now tighten (2) lower bolts to 57 in/lbs. (Fig 45 & 46)

29.Install injector driver ECU. Install (3) bolts using 10mm socket, then tighten to 57 in/lbs. Do not tighten until all bolts are installed. (Fig 47 & 48)

30.Installation complete!! (Fig 49 & 50) 31.Key on ignition to let fuel pump cycle and build pressure in fuel lines. Check all fuel lines for leaks. If you find a

leak, tighten any fittings and key ignition again to build fuel pressure. When no leaks are present, start the vehicle. The first startup may take slightly longer than normal.

Now enjoy your new fuel system, and added bonus of a 4 pound weight loss!


Questions, comments, or concerns? Email [email protected].


fr-s / brz / gt86 fuel rail kit - racer x fabrication · 21.install fuel rail dampers, be sure to...

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