I was wondering how to install the secondary fuel rails. I tried for about 45 minutes to push the rail (with insulator already on the rail) into the hole. Am I supposed to insert the insulator first?

 

I put the insulator into the boss on the lower intake manifold, spray it with some wd40 or silicone spray and gently insert the injectors and rail. You shouldn't have to force anything.

 

It seems as if the insulators are too small for the rail; so I have to stretch the insulator over the rail. Otherwise I cant get it to go in.

SO

Are you saying the secondary fuel rail and injectors sit on top of the insulator?

 

Someone has to know.

 

Yes. Put the diffuser in the boss in the lower intake manifold, then install the insulator. Then the rail sits on top of that. I usually install the injectors in the actual rail first then bolt it down as an assembly.

 

so should i take the diffuser out and reinstall it? i never took it out. the injectors are already in the fuel rail.

 

You're over thinking this one. RES has explained the steps. The diffusers are in the LIM boss openings. If you have already pulled them out, then you need to make sure you have them slotted back into position correctly (that is, they go in rotated a certain direction--see FSM if necessary). The insulator is placed in the boss on top of the diffuser. You then place the secondary rail on top of the insulator and compress it down mildly as you bolt down the secondary rail. That is how you create the seal for that opening. Nothing should be stressed if everything is installed correctly.

 

Check to make sure those diffusers ( air bleed sockets ) are inserted properly and "hit home". They have an "indexing" mark on top of them that fits in a slot in the iron. They might look like they are in place and in fact may not be. Double check. Refer to manual page F-106 " notches"

later

 

Can someone confirm the insulators in the parts manual are correct for each rail?. I pulled the rails once upon a time and noticed they were swapped. Meaning the thicker, smaller inner diameter (nf01-13-257a) were on the secondaries, and thinner, larger diameter (n3a1-13-257) were on the primaries. Now I am changing the hoses on the rails (long story) and bought new insulators and for the life of me installing the parts manual way is a p.i.t.a. secondaries are not pretty in place.

 

Never mind. Parts manual had it backwards. I installed it their way and created a huge headache for myself. Fortunately I had spares. The thicker, smaller diameter insulator goes on secondary rail. The thinner, larger diameter insulator goes on the primary rail. Should have followed my instincts for a change 😮‍💨