This DIY is for installing aftermarket fuel injectors and clips on a 2006 Civic SI. It can also be followed if you wish to replace the stock fuel rail. This thread is for informational purposes only. I accept no responsibility for any problems or issues that you may encounter. With that being said...Here we go!
Here is a PIC of the 650cc fuel injectors and replacement fuel injector clips that were supplied when I purchased the
All Japanese Performance Stage II turbo kit to include the Hondata reflash.
Begin by popping the hood and removing the two 10mm nuts on the cover shown in the below PIC.
After the cover has been removed, reinstall the two 10mm nuts for safekeeping. Next remove the one 10mm bolt that holds the fuel rail ground wire to the intake manifold and remove the four fuel injector connections by pressing each clip and lifting. Then use a flat head screwdriver and insert into the clips that hold the harness to the fuel rail and lift the harness.
This PIC shows the items mentioned in the above PIC removed.
IMPORTANT: For the next steps, make sure that you first loosten the gas cap to release excess pressure built up in the fuel system.
Remove the black plastic fuel line cover in the below PIC.
The following PIC shows the cover removed. Next, stuff a bunch of rags under this area to catch the gasoline that will end up spilling. Once completed, push on the top and bottom sections of the green clip in the below PIC and pull the fuel line off to the right. Use rags to clean up the gasoline that spills.
This PIC shows the fuel line after it has been removed.
Remove the two 12mm nuts that connect the fuel rail to the intake manifold as can be seen in the below PIC.
Under the fuel rail, you will need to then remove the U-clips that hold each of the stock fuel injectors to the fuel rail. Two of the four clips can be seen in the below PIC.
This PIC shows the U-clips removed from the stock fuel injectors.
Stuff a bunch of rags all around each fuel injector as gasoline will spill when the fuel rail is removed. Once complete, lift the fuel rail off of the injectors and swab up any gasoline. The following PIC shows the stock fuel rail removed. Next, remove all four of the stock fuel injectors by twisting and lifting up.
The below PIC shows the stock fuel injectors removed from the intake manifold.
The following PIC shows the stock fuel injector on the left and the 650cc fuel injector on the right. Before installing the new fuel injectors, be sure to put a little bit of dielectric grease on the upper and lower O-rings of each injector.
IMPORTANT: Do not use vaseline on the O-rings as this will cause them to swell over time. Instead, you should use dielectric grease to prevent the O-rings from twisting or rolling when being installed.
Lightly twist each fuel injector into the fuel rail and then reinstall the fuel injector U-clips.
As could be seen in previous steps, the 650cc fuel injectors are longer than the stock ones. In order to reinstall the fuel rail, you must use vice grips or some other tool to raise each of the two studs used to secure the fuel rail to the intake manifold. The below PIC shows one of the studs extended with the black stock spacer in place.
Next install a locking shaft collar (3/8" ID x 3/4" OD x 3/8" W) to take up the additional space created when raising the stud. Tighten the allen screw in the locking shaft collar to secure and then perform the same on the other stud.
IMPORTANT: Failure to use a shaft collar or other part to take up the additional space will cause the fuel injectors to contort when tightening the nut.
This PIC shows both locking shaft collars installed.
Install the fuel rail with 650cc injectors. Be careful when seating the fuel injectors and make sure that the raised bolts go through the two studs on the fuel rail.
Install the two 12mm nuts that connect the fuel rail to the intake manifold and tighten securely.
This PIC merely shows the spacing between the raised fuel rail and the rubber hose.
This PIC shows the fuel rail installed.
Next, use a small flathead screwdriver to push into each of the clips used to hold the cover on the fuel rail harness and open the cover.
This PIC shows the cover opened.
This PIC shows the cover removed.
Strip the shielding off of each of the fuel injector clips as can be seen in the below PIC.
This PIC shows the stock fuel injector clip next to the replacement fuel injector clip. When you snip the wires, be sure to add 1/2" to the new fuel injector clip so that the wires will be the same length as the stockers once connected.
The wires on the new fuel injector clip have been cut and shielding removed from the ends. Be sure to twist the ends of the wires.
Next, install heat shrink tubing onto the wire and twist the wire connections together (when doing this make sure that when each of the new fuel injector clips are installed onto the fuel injector, the positive wire is to the left and the negative wire is to the right). Use a soldering iron and resin solder (used for electrical connections) and solder the wires together. Move the heat shrink tubing over the area and use a heat gun to shrink. Do the same thing for the remaining three fuel injector clips. The following PIC shows the result.
Use electrical tape to carefully wrap each of the fuel injector clip wire leads.
Reinstall the fuel injector harness into the cover and snap secure.
Snap the cover back onto the fuel rail, push the new fuel injector clips back onto each fuel injector (see important note at the end of this post), reinstall the fuel rail ground wire, and tighten the 10mm bolt for the ground wire.
Reconnect the fuel line.
Reinstall the black plastic fuel line cover.
Before starting the car, be sure to turn the key to the on position for about five seconds. This will ensure that pressure in the fuel system is returned before cranking. It would also be a good time to check all connections for any signs of a leak (you should not have any, but it never hurts to double check things).
Remove the two 10mm nuts that are used to hold the cover secure. Reinstall the cover and two 10mm nuts and then tighten.
Important: If you are following the above steps as part of a turbo kit installation, then you want to make sure that the fuel injector clips are disconnected from the fuel injectors. After all other parts of the turbo kit have been installed, crank the car over for about 15 seconds. This will pressurize the oil system and prime the turbo seals with fresh oil. After this is complete, connect the fuel injector clips onto the fuel injectors. At that point, you can then start the car. 