"How-to" - Setup and Installation

This section is setup to provide Keith's rail kit users some general instructions for installing their kit. Please keep in mind this is only a suggested setup and there are many other ways to setup your rails and fuel system. Your car setup may vary and have different requirements than what is listed here. If you have any questions feel free to e-mail them (please provide picture when possible for specific questions). This section is divided into 3 sections to segment the installation process. All tools, parts, and estimated times are included in this writeup for the pictured setup. The sections of this write-up are:

Part I - Assembling the Rails

Part II - Harness Replacement (for low impedance injectors)

Part III - Rail Installation

This How-to assumes you already have your manifold and stock rails removed and that your fuel system has already been designed to accomidate these rails. Other "how-to" write-ups are available for manifold removal and fuel system setups on the web.

Part I - Assembling the Rails
Tools required Large adjustable wrench 3/4 " open/boxed end wrench 1/8 " Allen wrench Teflon Tape Medium size Flat Head screwdriver 3/4 " Deep Socket and Socket Driver	Parts Required 1-Keith's Rail Kit (cost $215 ) 2-4 x 3/8 " NPT fittings (recommended 3 x AER-FCE2005 and 1 x AER-FCE2035 for those doing 6AN lines and nickel finish fittings as pictured) (approx cost $35)	Estimated Time 15 minutes
	Rail kit pictured as shipped. Click on picture for larger image.
See primary rail pictured on Step 3.	Step 1. Reverse primary mount using flathead screwdriver.
no picture available at this time.	Step 2. Tighten all screws on secondary rail using flathead and 1/8" allen wrench.
	Step 3. Put desired 3/8 " NPT fittings on rails using PTFE Thread sealant tape (teflon). Pictured incorrectly to left - note red "X" where wrong fitting intially used - ended up using AER-FCE2035 instead (click on image for full size picture). When choosing the fittings keep in mind that the clearance between the front of the primary rail and the front secondary injector is tight and requires at least a 45 degree NPT fitting. Teflon tape should be used on all NPT fittings but not on AN fittings. Make sure not to tighten the secondary fittings too far - it is possible to block the injector inlet (although getting it that tight would take a huge amount of force).
Part II - Harness Replacement (for low impedance injectors)
Tools Required Diagonal Snips Wire strippers Soldering Iron / Solder Heat Shrink Lighter	Parts Required 1. 4 x Injector Harness (Pictured - GM Multi-port Fuel Injector Socket Calterm Part #08653) (approx cost $6) 2. 4 x 10 ohm, 10 watt resistors (Radio Shack Part # 271-132) (approx Cost $5)	Estimated Time 45 minutes
	Step 1. Snip one wire of the harness back to fit as pictured. (does not matter which wire)
	Step 2. Place heat wrap on short wire. Strip the short wire. Loop wire and resistor together and solder. Cover solder connection with heat wrap and melt with lighter.
	Step 3. Repeat Step 1 and 2 for all harnesses.
	Step 4. Loop ends of resistors and setup heat shrink. (as pictured in step 3.
	Step 5. Snip stock harnesses from engine harness. Shown by red arrows (click on picture to left for full size pictures).
	Shown snipped.
	Step 6. Solder new harness into engine harness and cover with heat wrap and melt. Does not matter which wire to which.
Part III - Rail Installation
Tools Required 1/8 " Allen wrench ? Allen wrench ? Allen wrench Razor Blade 11/16 " Open end wrench 3/4 " Open end wrench	Parts Required 1. Connectors to fuel system (6AN to auto-fit installed on stainless pictured) 2. 5/8 " ID hose - about 5 inch length (cost approx $1) 3. 2 x 8mm x 30mm x 1.25 thread bolts (purchased from Lowe's Hardware) (cost approx $3)	Estimated Time 30 minutes
	Step 1. Remove lower rear bolt for Block off Plate on the inside of the lower intake manifold. Replace with Hex bolt included in kit.
	Step 2. Slightly lubricate top of secondary injector o-rings with oil. Insert secondary injectors into secondary rail.
	Step 3. Temporarily seat secondary rail on lower intake manifold. Note the gap size left between bottom of seated injector and the lower intake manifold. Cut a sliver of the 5/8" hose slightly larger than this gap to make custom insulator. Remove rail/ leaving injectors in rail and install custom insulator on both injectors (primaries pictured).
No picture avialable at this time.	Step 4. Connect fuel lines to secondary rail (this may be required before rail installation depending on access to both fittings after rail is in). Install secondary rail on to lower intake manifold using remaining 2 hex bolts included with the kit.
	Step 5. Slightly lubricate top of primary injector o-rings with oil. Insert primary injectors into primary rail.
	Step 6. Temporarily seat primary rail on engine. Note the gap size left between bottom of seated injector and the engine. Cut a sliver of the 5/8" hose slightly larger than this gap to make custom insulator. Remove rail/ leaving injectors in rail and install custom insulator on both injectors.
	Step 7. Connect fuel lines to primary rail (this may be required before rail installation depending on access to both fittings after rail is in). Install primary rail on to engine using remaining 2 8mm bolts (original bolts are too long to use with new rails).
	Picture of completed installation.