DIY Network

Mopar Turbo-Upgrade: Fuel Injectors, Pt. 1 From "Tricked Out" episode DTRK-110

	Performance specialist Gary Howell of Howell Automotive®.

In this episode of Tricked Out, host Andrew Totolos installs a turbo performance upgrade -- including new high-flow fuel injectors and performance control module -- on a 2003 Dodge Neon. In this third segment, Andrew and Gary continue the upgrade by readying the car for the new fuel-injection system. To do this, they must first remove the factory-installed fuel rail from the intake manifold.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Mopar Stage-1 kit, including:

• Set of four 527-cc/minute fuel injectors
  
• Mopar performance power-trained control module
  

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

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	Figure A
	Figure B

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 (figure A), 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 (figure B).

• Disconnect the negative battery cable once again. The fuel system is now ready for installation of the new injectors.

• Safety Alert: 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 (figure C).

• The next step is to disconnect the fuel line. Before you do, stuff a rag around the line fitting to absorb any spilled fuel (figure D).

  Figure C

  Figure D

  
  

• Squeeze the retainer tabs together to release the fitting, and use another rag around the line to catch any spilled fuel (figures E and F).

• Safety Alert: Fuel-soaked rags can spontaneously combust. Keep them outside in an open metal container until they can be disposed of properly.

  Figure E

  Figure F

  
  

• The fitting on the fuel rail can be sealed off with a vacuum cap (figure G).

• Unplug the mass airflow sensor (figure H).

  Figure G

  Figure H

  
  

• 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 (figure I). 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 (figure J). You'll need a deep-well socket to get them out.

  Figure I

  Figure J

  
  

• 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 (figure K), 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 (figure L).

  Figure K

  Figure L

  
  

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps 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 precautions that come with your kit or replacement parts.

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Special Resources for Tricked Out, episode 110

Howell Automotive
Website: www.howellautomotive.com