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Old 06-24-2002, 11:22 AM   #1
Carlo
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Default STI Injector Installation Instructions

I've searched high and low for STI Injector Installation Instructions and my searches have come up short.

Does any body have instructions for this, that they could post?

From a quick check under the hood it would appear that the Intercooler, Airbox and Washer Reservoir needs to be removed.

What else needs to be removed to get to the point of being able to remove the fuel rails?

Does anything special need to be done to purge the fuel out of the system before removing the fuel rails?

Do the injectors just pop out with a little tug and the new STI injectors snap in?

Any special things to watch our for (aka little gotchas)?

From a technical standpoint of how hard this is to do. How would this compare to say an uppipe installation (easier/harder)?

Thanks,
Carlo
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Last edited by Carlo; 06-24-2002 at 11:31 AM.
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Old 06-24-2002, 12:54 PM   #2
bobgrice
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I personally have not done this mod, but I will and I have studied the area pretty closely and listened to others.

I think the main problem people run into is the "green brackets of death". These are thick metal brackets that I believe are to protect the fuel system in the event of a crash. Most people do not put them back on.

There are a couple of bolts that hold these brackets on that are impossibly hard to get to. Most have persevered and made it through, but some have stopped short because of these brackets.

I will also say that there are numerous discussions on this board on this installation. Try searching for posts in FFI from late last year, which was when a lot of people were doing the swap for the first time. There should be some info here and it will help to narrow your search.

Good luck & have fun.
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Old 06-24-2002, 01:53 PM   #3
NotoriousWRX
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Try looking in Jorge's site.

www.projectwrx.com
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Old 06-24-2002, 02:18 PM   #4
RiftsWRX
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Quote:
Originally posted by NotoriousWRX
Try looking in Jorge's site.

www.projectwrx.com
Back in like march I did a video install but never attached any of the audio to it... it's huge... but here it is if you wanna use it...

http://www.projectwrx.com/racevids.htm

if you can dig up the written directions around here, this should at least help you get going...

Jorge (RiftsWRX)
www.ProjectWRX.com
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Old 06-24-2002, 03:01 PM   #5
roybfr
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Here are two sets of written instuctions I got off the board that I used to assist in the install. Sorry to whoever wrote the second set for not giving proper recognition, the other was written by ScoobySnax.

The only things I have to add to them is to empty out the coolant. Yes yon can do it with out it, but it makes for less of a mess and no trying to quickly plug stuff in a small space. Just remeber to refill it. Buy a Craftsman or other double sided 12mm/14mm box wrench for the fuel shield bolt behind oil breather on the passanger side. It is a PITA, even with the long box wrench you only get about 1/5 a turn, but after a few turns you can remove it with your finger. The drivers side shield came out fine after some wiggling, but the passanger side got caught up against the wastegate on my VF30, so I just cut it into three pieces and removed it since I was not going to reinstall the bracket. Once you unbolt the fuel rails the injectors come out pretty easily.

Troy

Well this might be a bit of a long post but I thought I'd give some info since there isn't much out there....and I had a BITCH of a time getting it done...

Overview:
Some people say you have to drain the coolant and remove some coolant lines but I did it all without. The hardest part is getting the injectors up high enough to clear the spot they sit in.

1. Remove the Intercooler (if you need instructions on this, post a reply)

2. Remove the rubber hose on the driver's side going down to the green bracket covering the Injectors

3. Remove the windshield washer tank by unhooking the connectors and swiftly pulling the hoses off. Drain tank into another container for easy re-installation.

4. Unscrew all bolts holding on the green bracket (driver's side). There's one on the back facing the car's firewall; a bit hidden but its there...

5. Unscrew the screws holding the fuel lines together near the top of the intake. This will make it much easier to get the injectors out. There is one screw near the bottom/front close to where you removed one of the bolts for the green bracket...be sure to get this one too.

5a. Unclip the wiring plug for the rear injector harness near the back of the green bracket. This will make it possible to remove the green bracket.

6. Wiggle and snake the green bracket out by pulling and cleverly twisting it. It will eventually come out at a downward angle as you slide it toward the car's firewall--->

6a. Unclip the wiring plug for the front injector harness.

7. You should be able to see the two injectors now. This is where things get a bit fuzzy (I did mine about 1-2 months ago). By removing the fuel rail screws up top and near the bottom in the front, you should be able to pull the fuel rail up. The injectors should come up with it as they are suctioned to the fuel rail. Pull down on them to take them off the rail. Move the fuel rail around so you can sneak the injectors out.

8. BE SURE TO CHECK EACH INJECTOR FOR A SMALL RUBBER SEAL BEFORE INSTALLING!!!! I removed both injectors on the driver's side and only one had the small rubber seal....the other one was stuck in the hole....not a problem unless you don't notice it until things are put back together

9. Its a good idea to smear a slight amount of general purpose grease on the rubber seal. Install both, re-install by repeating everything in reverse.

10. The passenger side is pretty much the same. You'll have to remove the front air intake system if you have a CAI and/or airbox. The green bracket is tough to get off but it does come out without removing any of the coolant lines!

11. Repeat the same process as above. There are some fuel rail screws which must be removed to allow free movement so the injectors can come out.

12. A handy tip: Keep the intercooler w/hoses intact near a heat source for easy re-installation. I spent almost 2 hours trying to get the intercooler hose to slide onto my VF30. The dudes from Subaru suggested I heat it up with a hair dryer for a few minutes....afterward it slid on in 10 seconds!!!

Hope this helps. I know I searched the world for something like this the day I got mine.

Cheers!

ScoobieSnaX

No need to remove your intercooler... You can remove the back bolt attaching the driver side green cover with just a short 12 mil wrench or socket. I agree with all of your other steps though... You can do this in just under 2 hours, or if you're real good, you can do this in about an hour

__________________________________________________ __

Not sure who wrote this one.

ok, first things first:

Take off the I/C

Passenger Side:

the coolant tank has four bolts holding it on. Disconnect the overflow hose and the other smaller diameter hose well. Clamp off the 2nd hose at it'll leak.

Remove any hose brackets and take out the bolts. You can then flip the coolant tank on its side (rotating it towards the drivers side of the car). This will give you exposure to the fuel rail shields.

There are 5 bolts holding on the fuel rail shield. Three are easy to get to. One hard one is in the bottom rear and is block by the cam sensor (unplug it now if you want, changes are you'll need to later on anyway just to get the shield out). I used a box wrench at very small rotations to loosen it up. The other hard bolt is behind the shield and the valve cover vent hose. I could not get any ratchet in there. I snaked a small wrench in there and used one find to hold the head of the wrench on the bolt and my other hand to lever the wrench to get it loose. Once they were loose, I used my fingers to get them all the way out.

Manuevering the shield out of the engine bay is quite an engineer feat and is best solved by yourself. Wiggle, move things, get it out.

Unplug the power connectors to the injectors


The fuel rail itself has three bolts, two directly between the injectors and one on the front of the head. They're all easy to get to.
----------------------------------------------------

Drivers Side:

Unbolt the negative terminal of the battery.

Unscrew the two bolts holding the windshield fluid resevoir to the wheel well. It will then lift out and allow you to flip/rotate it onto the battery without having to undo any connectors or hoses.

Unbolt the grounding terminal cable on top of the manifold. Its in the way.

There are only four bolts holding this shield on. All are easy to get to, though manuevering it out is still a pain. Once again, unplug the cam sensor and the injectors connections.

There are three bolts on this fuel rail also just like the other side, two in the middle, one on the front of the head. You will also want to undo the bolt which stabilizes the fuel rail to the top of the manifold. It'll let you lift the rail easier.


Depressurize the fuel system (open fuel cap, pull green relay under the dash and crank engine for 2-3 minutes)

Lift the rail up (slight bending of rail will take place) and pull injectors out.
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Old 06-25-2002, 01:39 AM   #6
Carlo
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Thanks everybody!

At around 11pm I lifted up the hood and got busy. Did the driver's side, took a break and went for a quick swim, then did the passenger side. Just got done a few minute ago.

I really wished I did the passenger side first because I almost quit. That one bolt under the green bracket towards the rear was almost a "show" stopper. I drank 2 beers while trying to figure that one out. Finally got it with a wrench from behind. I just couldn't get enough leverage on the wrench from the front.

Anyway, the install was pretty much what I expected but having the video on hand and the written instructions helped.

Thanks,
Carlo
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Old 06-25-2002, 08:39 AM   #7
nhluhr
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did you install the injectors without any additional tuning? How does it run?
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Old 06-25-2002, 09:07 AM   #8
Tuning Factory Inc.
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It's not that hard folks. A few bolts and take off/put on. YOu don't have to even remove the rad overflow tank. Just have someone hold it out of the way.
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Old 06-25-2002, 09:58 AM   #9
roybfr
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Sure for the most part it is just unbolting a few bolts and wiggling out some brackets, taking out some more bolts, pop old injectors out, new in, rebolt everything and go. It is just easy to get frustrated with the bolt on the passanger side and wiggling the brackets out the first time. I agree though that after doing it once subsequent times would be much easier. Unfortunately some of us are losers and don't have friends to hold the coolant take for us so emptying it is the way to go, and that only adds a few minutes. For those that can do it in 1hr more power to you, but the average guy who only works on his car from time to time it is going to take longer.

Troy
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Old 06-25-2002, 11:30 AM   #10
Carlo
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I did it by myself and didn't drain anything. I also didn't disconnect any tubing except one hose going into the coolant tank on the passenger side at the bottom. On the driver's side "green bracket" at the back there is a hose connecter that was wedged into the bracket (or maybe it is attached) so I also disconnected both hoses attached to this. The windshield washer tank lifts up and can easily be moved to sit on top of the battery without removing any hoses from it.

I didn't have any coolant or oil spills or leakage. The only thing I did that was maybe pro-active was take the gas cap off. I have no idea if this made a difference or not. I also didn't do the engine turnover to get rid of any remaining fuel. I didn't think there would be much left around the injectors. When I lifted the fuel rails up about a 1 or two of fuel spilled out where the injectors are at. That was the only "spillage" I saw.

I actually pulled the passenger side green bracket out of the car (left it out) but the drivers side I just moved out of the way and put it back in place after I installed the STI injectors.

Overall, I'd rate this a 5 on the hardness scale (1 to 10). In case anybody is wondering how this compares to other mods:

1) TurboXS Unichip,
Change Muffler,
Oil Change
1 or 2) Catback Exhaust
2 or 3) Turbo Back Exhaust,
VishnuPerformance Unichip (without harness)
3 or 4) Pulley Kit
5) STI Injectors
7 or 8) Upgraded Turbo
10) UpPipe

Carlo

Last edited by Carlo; 06-25-2002 at 12:18 PM.
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Old 06-25-2002, 12:02 PM   #11
roybfr
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I am sure some of my added frustration was due to being tired from working on the turbo and uppipe before hand, which I felt was pretty easy but just time consuming. I just wanted to get it done so I could drive my car.

I also had only dribbles of fuel come out when I pulled the injectors. I had read alot about it squirting all over at a million psi, I think that was a little over stated, just like my whining about the one green bracket bolt and wiggling the brackets out. Oh well at least I can admit when I am being a whiner.

Glad that you got it done and had few problems.

Troy
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Old 06-25-2002, 12:30 PM   #12
Austin
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After I put new injectors in, I left those silly green brackets off.

I also drained and removed the coolant tank - it made everything a little easier to get to, especially with one person.
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