Assembly-Injectors/Intake Plenum

1. Lay out both new fuel rails and new hardware supplied with this campaign. Note the new spring type clamps.

2. Tape the spacers in place on the injector holders with masking tape.

3. Using a clean, fiber free applicator, such as a plastic coffee stirrer, lubricate the inside of all of the fuel hoses with a small amount of the Daifloil # 10 that is provided with this campaign. Do not use cotton swabs or similar type applicators.

CAUTION:
DO NOT use any type of cleaning solvents on the hoses supplied in the kit.

DO NOT use any oil/lubricant other than the Daifloil # 10 oil supplied in this campaign. Other oils/lubricants can react with the pre-applied adhesive on these replacement hoses.

4. Lubricate the inside and outside of the lower injector insulators with the Daifloil # 10 oil and insert the insulators into the intake manifold.

NOTE:
Before installing the fuel rail assemblies, check all injector tips for damage.

5. Install the fuel rail assemblies. Set the assembly over the intake manifold and connect each fuel rail to the fuel regulator. Connect the crossover hose.

6. Lower the injectors into the injector insulators in the manifold and install the holder bolts and fuel rail bracket bolts. Torque the injector holder bolts to 22 - 28 in-lbs (2.3 - 3.2 N.m). Torque the fuel rail bracket bolts to 13 - 16 ft-lbs (18 - 22 N.m).

7. Install the fuel rail inlet hose provided with the injector kit. Tighten the hose clamps by hand. A clamp is properly tightened when a dime will just fit into the gap.

8. If the fuel filter did not meet the requirements as stated under Service Procedure, then replace it with a Genuine Infiniti fuel filter. When replacing the fuel filter, also replace the frame-to-filter hose.

NOTE:
An over tightened clamp may damage the hose and cause a fuel leak.

9. Inspect the injector connectors for damage. If any type of damage is found such as broken connectors worn terminals due to corrosion, pins pushed in or bent, install a connector kit using the procedure under Injector Connector Kit Installation in this bulletin. If an injector connector does not need replacement. continue with this procedure.

10. Attach the injector connectors to the fuel injectors.

11. Blow all dirt and dust from the intake manifold. Be sure to wear protective goggles and a respirator when removing dirt and dust. Remove the plastic intake manifold plugs and air duct cover.

12. Brush or spray a small amount of Permatex(R) High Tack Adhesive Sealant P/N 98H on the intake manifold and set the gasket in place.

13. Remove the plastic intake plugs from the plenum. Lower the plenum over the engine align the air duct with the air intake, and rotate the plenum into place on the manifold. Be sure the air duct and wiring harness are not damaged during installation.

14. Install the intake manifold bolts, and torque them to 13-16 ft-lbs (18 - 22 N.m).

15. Install the air duct to the throttle body and tighten the clamps. Verify the clamps do not interfere with throttle operation.