APS Fuel System Installation Guide
 

   

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Model No.: APSWRX-FRP/03
Description: FUEL RAILS/PLUMBING - STOCK INJECTORS
Application: TOP FEED INJECTORS
Item
No.
Part No.
Description
Qty.
1 995-076-050 FUEL RAIL - Standard Injector - RHS 2
2 995-076-900 BRACKET - Fuel Rail Mtg. 2
3 000-094-300 BOLT - B/H Cap Screw 4mm x 0.7 x 20mm - S/S 4
4 000-042-400 BOLT - S/H Cap Screw 8mm x 1.25 x 16mm - S/S 4
5 000-631-100 ADAPTOR - ST. - 9/16" JIC x 3/4" SAE 2
6 000-607 ADAPTOR - ST. - 9/16" JIC x 1/4" NPT 2
7 000-685 ADAPTOR - TEE - 9/16" JIC 1
8 995-809-800 HOSE ASSEMBLY TEFLON - 5 x 420mm - 90°/90° 1
9 995-809-100 HOSE ASSEMBLY - 5 x 240mm - ST./ST. 1
10 995-809-200 HOSE ASSEMBLY - 5 x 510mm - 90°/ST. 1
11 995-809-300 HOSE ASSEMBLY - 5 x 660mm - 90°/45° 1
12 995-853-200 HOSE ASSEMBLY - PUSHLOC - 5 x 1200mm - ST. 1
13 000-853-112 HOSE - PUSHLOC - 5 x 1120mm 1
14 000-002-100 BOLT - Hex - 6mm x 1.0 x 14mm (SEMS) 3
15 995-754-100 BRACKET - POWER STEERING HOSE MTG 1
16 995-073-700 BLOCK - REGULATOR MOUNTING 1
17 995-073-750 BRACKET - REGULATOR MOUNTING 1
18 000-931 CLAMP - HOSE SUPPORT 15/20mm 2
19 000-916 CLAMP - HOSE - FUEL INJECTION (14) 3
20 000-052 BOLT - S/H - 8mm x 1.25 x 50mm 1
22 000-827-100 HOSE - Rubber - Vacuum - 3.0mm x 1000mm 1
23 000-992-020 SPACER - 8mm ID x 20mm OD x 20mm LONG 1
24 000-862-110 HOSE - Emission 6.4mm x 1100mm 1
25 000-987-178 TIE STRAP - NYLON 178mm 5
26 000-302-300 S/S WASHER FLAT 8mm 1
27 000-305-200 WASHER STAR 8mm 1
28 000-912-100 CLAMP - Spring - 9.5mm 1
29 000-912-200 CLAMP - Spring - 10.3mm 1
30 000-631-200 ADAPTOR - St. Ext. - 9/16" JIC x 3/4" SAE 2
31 000-003-100 BOLT - Hex - 6mm x 1.0 x 20mm (SEMS) 2

APS Fuel System - APSWRX-FRP/03

1

Remove the stock intake manifold and tumbler valves in accordance with the factory service manual.
2 Remove the stock fuel rails, regulator and fuel lines in accordance with the factory service manual.
3 Reinstall the tumbler valves to the cylinder heads.
4 Apply rubber grease to the long 9/16" JIC x 3/4" SAE adaptor O-ring (Item 30) and the short 9/16" JIC x 3/4" SAE adaptor O-ring (Item 5) and install into the LHS fuel rail (Item 1) as shown.

Install the fuel rail mounting bracket (Item 2) to the LHS fuel rail (Item 1) and retain using 4mm x 0.7 x 20mm stainless steel screws (Item 3).

Insert the 8mm x 1.25 x 16mm stainless steel socket head mounting bolts (Item 4) into the fuel rail mounting bracket (Item 2) in preparation for installation.

5 Apply rubber grease to the long 9/16" JIC x 3/4" SAE adaptor O-ring (Item 30) and the short 9/16" JIC x 3/4" SAE adaptor O-ring (Item 5) and install into the RHS fuel rail (Item 1) as shown.

Install the fuel rail mounting bracket (Item 2) to the RHS fuel rail (Item 1) and retain using 4mm x 0.7 x 20mm stainless steel screws (Item 3).

Insert the 8mm x 1.25 x 16mm stainless steel socket head mounting bolts (Item 4) into the fuel rail mounting bracket (Item 2) in preparation for installation.

6 Install the LHS and RHS fuel rail assemblies to the tumbler valve housings and secure with the 8mm x 1.25 x 16mm stainless steel socket head mounting bolts (Item 4).
7 Apply thread sealant to the two 9/16" JIC x 1/4" NPT straight adaptors (Item 6) and install into the regulator mounting block (Item 16).

Install the regulator mounting block mounting bracket (Item 17) to the regulator mounting block (Item 16) and retain with two 6mm x 1.0 x 14mm (SEMS) bolts (Item 14).

8 Pass a 15/20mm hose support clamp (Item 18) over the 5 x 1200mm fuel supply hose (Item 12) and install the 9/16" JIC Tee adaptor (Item 7) to the fuel supply hose (Item 12) as shown.

Install the fuel regulator mounting block assembly to the hose support clamp (Item 18) using a

8mm x 1.25 x 50mm socket head bolt (Item 20), a star 8mm washer (Item 27) a flat 8mm washer (Item 26) and a 8mm ID x 20mm OD x 20mm long spacer (Item 23) as shown.

9 The following steps describe the installation of the fuel hoses etc. however it is strongly advised that you use this image (that is provided as a logical overview) to become familiar with the overall fuel circuit.
10 Install the stock fuel pressure regulator to the regulator mounting block (Item 16).

Install the fuel regulator assembly to the stock earth bracket using the 8mm x 1.25 x 50mm socket head bolt (Item 20) installed earlier through the regulator block mounting bracket (Item 17).

Route the 5 x 420mm - 90°/90° LHS fuel supply hose (Item 8) as shown and install onto the long 9/16" JIC x 3/4" SAE (Item 30) on the LHS fuel rail (Item 1) and the 9/16" JIC Tee adaptor (Item 7).

11 Route the 5 x 660mm - 90°/45° RHS fuel supply hose (Item 11) as shown and install onto the long 9/16" JIC x 3/4" SAE adaptor (Item 30) on the RHS fuel rail (Item 1) and the 9/16" JIC Tee adaptor (Item 7).

Route the 5 x 510mm - 90°/ST RHS Return Fuel Hose (Item 10) as shown and install onto the short 9/16" JIC x 3/4" SAE adaptor (Item 5) on the RHS fuel rail (Item 1).

12 Install the LHS Fuel Return Hose (Item 9) between the 9/16" JIC x 1/4" NPT straight adapter (Item 6) on the regulator mounting block (Item 16) and the short 9/16" JIC x 3/4" SAE adaptor (Item 5) on the LHS fuel Rail (Item1).

Install the 3.0mm x 1000mm rubber vacuum hose (Item 22) to the fuel pressure regulator vacuum port.

The remaining hoses shown will be installed at a later stage.

13 Route the 3.0mm x 1000mm rubber vacuum hose (Item 22) from the fuel pressure regulator vacuum port as shown.

Check that all hoses are routed and laid out as shown in preparation for the installation of the stock intake manifold assembly.

14 Install the stock intake manifold.
15 Install the new purge hose (Item 24) to the blue Tee piece at the front of the intake manifold and connect the other end to the stock metal line above the fuel filter. Retain with spring clips (Item 28 and 29).
16 Install the 3.0mm x 1000mm rubber vacuum hose (Item 22) from the fuel pressure regulator vacuum port to the vacuum port in the intake manifold.
17 Install the 5 x 1200mm fuel supply hose (Item 12) and the 5 x 1120mm fuel return hose (Item 13) as shown and retain with fuel injection hose clamps (Item 19).

Use 178mm plastic tie straps (Item 25) to support the hoses.

Route the fuel supply and return hoses (Items 12 & 13) down and back towards the firewall.

Support the fuel supply hose (Item 12) with a cushion clamp (Item 18), attached to the inboard attachment stud of the stock master cylinder to the vacuum assist unit.

18 Route the fuel supply and return hoses (Items 12 & 13) up to the fuel pressure regulator area as shown.

Install the fuel supply hose (Item 12) to the 9/16" JIC Tee adaptor (Item 7).

Install the fuel return hose (Item 13) to the bottom of the stock fuel pressure regulator and retain with a fuel injection hose clamp (Item 19).

19 Install the power steering pipe support bracket (Item 15) and retain with two 6mm x 1.0 x 20mm (SEMS) bolts (Item 31) and one 6mm x 1.0 x 14mm (SEMS) (Item 14) bolt as shown.
20 Verify that all hose clamps and fasteners are tightened.
21 Refill engine coolant and check all other fluid levels.
22 Verify that all components which are affected by engine movement have sufficient clearance to adjacent body panels and other components.
23 Ensure that fuel hoses - particularly those that are stainless steel braided cannot rub or vibrate against any other components.
24 Turn the ignition key on and off several times to pressurize the fuel system and check for any leaks. Pay particular attention to the area around fittings and adapters.