Jeep 4.0 Fuel Rail Install Instructions

Installing the NRT Autosports Aluminum fuel rail isn't too complex, but due to fire risks the installation should be performed by a qualified automotive professional

Here's a general guide:

Materials and Tools Needed:

1. NRT Jeep 4.0 Aluminum fuel rail kit

2. New Injector O-rings (Recommended but not Provided)

3. 10 MM Socket wrench

4. Fuel line disconnect tool

5. M4 Allen Key

6. 3/8" Allen Key

7. 12mm wrench

8. -8 AN wrench

9. Rag or shop towels

10. Petroleum/Synthetic Based lube

11. Thread lock
    

Steps:

1. Prepare the Work Area: Ensure the engine is cool. Disconnect the battery

2. Relieve Fuel Pressure: Depressurize the fuel system to avoid fuel spray. This is done by locating the Schrader valve on the fuel rail and using a small screwdriver to press the pin inside while catching the fuel that sprays out with a rag.

3. Remove the Old Fuel Rail: Disconnect the Fuel Line from the quick connect port. Unscrew the bolts securing the fuel rail to the intake manifold. Carefully lift the old fuel rail and injectors out of the manifold.

4. Replace the O-rings: If you're reusing injectors that haven't been in for a long time you may be able to reuse the O-rings, but remember to thoroughly inspect and replace the O-rings if necessary. Lubricate the new O-rings with a Petroleum based or Synthetic based grease before installing them into the Fuel Rail and Intake Manifold

5. Prepare NRT Fuel Rail: Install -8 ORB Cap on the rear of the rail and the 1/8 NPT to -8 ORB adapter on the front of the rail. Install the Aluminum Fuel Rail mounting brackets to the bottom of the rail using the provided counter sunk screws. Apply a small amount of thread lock to the threads of the screws.

6. Install the New Fuel Rail: Place the new fuel rail into position on the intake manifold. Insert the injectors into their respective ports on the fuel rail and press them firmly into place.

7. Secure the Fuel Rail: Using the OE bolts from the original rail secure the fuel rail to the intake manifold. Be careful not to over-tighten the bolts, as this can damage the manifold.

8. Install Fuel Pressure Gauge: Locate the 1/8 NPT to -8 ORB adapter installed on the front of the fuel rail. Mark the 12 o'clock position and remove from fuel rail. Hold NPT adapter in a vise using a set of soft jaws to prevent damage. Thread the fuel pressure gauge into the NPT adapter by hand until it you start to feel resistance. Tighten the gauge the rest of the way using a 12mm wrench. DO NOT TWIST BY THE FACE OF THE GAUGE TO TIGHTEN! using a 12mm wrench line up the "40psi" mark and the center line mark made on the NPT adapter. reinstall the assemble in the fuel rail and tighten using a -8 AN wrench

9. Connect Fuel Line: Reattach the OE fuel line or if you opted for the NRT Autosports Fuel Line to the quick connect port disconnected earlier.

10. Repressurize the Fuel System: Reconnect the battery. Turn the ignition key to the "On" position without starting the engine. Listen for the fuel pump to prime the system (usually a faint whirring noise). Check for leaks!

11. Final Checks: Once you're confident there are no leaks and everything is securely in place, start the engine and let it run for a few minutes. Check again for leaks and ensure everything is functioning correctly.