Installation Instructions Replacement of recalled SUM MAX-efi 500 fuel injection kit (FiTech campaign 18E-029)

Transcription

1 Installation Instructions Replacement of recalled SUM MAX-efi 500 fuel injection kit (FiTech campaign 18E-029) WARNING! To reduce risk of fire or accident, including loss of engine power possibly resulting in vehicle crash, immediately inspect your vehicle to determine if you have a recalled MAX-efi 500 kit. Injector O-ring failure may or may not be preceded by inconsistent fuel metering, fuel odor from hood area, leaks or visible fuel signatures on or around fuel rails and throttle body. DO NOT USE VEHICLE UNITL YOU HAVE REPLACED FUEL RAILS PER THIS RECALL. This installation process should take 1-hour or less. It is our desire to assist you during this process and if at any time you have any questions to the process or these instructions, please call us at or at PSN@FiTechEFI.com. You can do this update with the unit installed on your engine or on a bench. The following instruction is of the unit on your bench. The instructions are the same for engine mounted units. Your kit consists of: 2 Fuel Rails (Identified by a single asterisk on the end of the rail) 9 O-Rings 3.5 x 7 BUNA-N 2 Seal, Nylon 9/16 D x Seal, Nylon 9/16 D x Banjo Fittings, 9/16-24 x 33mm 1 Dielectric O-Ring grease 1 Allen Wrench M5

2 Tools you will need 1 3/4 Open-end wrench 1 11/16 Open-end wrench 1 Adjustable Wrench 1 Curved Pick 1 Allen Wrench M5 (supplied) NOTE: DO NOT use any power tools during disassembly and reassembly WARNING! Gasoline vapors are explosive. Assure there are no sources of combustion (ex. water or other heaters) within work area. Cool motor and disconnect battery before starting this replacement. Have rags or pads ready to absorb any spilled fuel. (For California Residents) WARNING: This product can expose you to gasoline and its vapors containing chemicals including toluene and benzene which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to

3 Step 1 Disconnect the negative side of your battery. Disassembly Step 2 Loosen banjo fittings on both the left and right rails using your 11/16 or adjustable wrench.

4 Step 3 After you have loosened the banjo fittings, continue to remove them by hand. Do not use any power tools as these may cause damage to fittings and or threads. *You will not need the seals or the banjo fittings that came pre-installed on your Summit MAX-efi 500. You can throw these away. Step 4 Turn throttle body around and use adjustable wrench to loosen the end cap fittings.

5 Step 5 After you have loosened the end cap fittings, continue to remove them by hand. Do not use any power tools as these may cause damage to fittings and or threads. *You will not need the seals that came pre-installed on your Summit MAX-efi 500. You can throw these seals away. You will be reusing the end cap fittings. Step 6 Looking down at the top of the throttle body, you will see there are 4-Allen cap screws that hold the fuel rails to the throttle body.

6 Step 7 Starting with the right side of the throttle body. Loosen and remove the 2-Allen cap screws with the supplied Allen wrench. *Set these screws to the side as you will be reusing them for re-assembly. Step 8 With gentle and constant pulling pressure, remove the right fuel rail. You may have to gently wiggle the fuel rail.

7 Step 9 Now that the fuel rail has been removed, you can remove the two injectors with gentle and constant pulling pressure. You may have to gently wiggle the injectors while applying gentle and constant pressure to relieve the suction on the O-ring.

8 Step 10 Using your curved pick tool, gently insert the tool end between the O-ring and injector and remove the brown O-ring from the injector end. You will not be reusing this O-ring and it should be thrown away to ensure it is not mixed with the new O-rings. Step 11 Repeat Step 10 with the second O-ring which is black on the opposite end of injector. You will not be reusing this O-ring and it should be thrown away to ensure it is not mixed with the new O-rings.

9 Reassembly Step 12 Reassembly of the injectors uses two, different stacked O-rings on each injector. First, carefully Install the new black O-ring to the injector end. Starting with one side of the O-ring slip it onto the injector while applying gentle pressure. You may need to use both hands to slide the O-ring onto the injector. Step 13 Repeat Step 12 - with the second O-ring which is black on the opposite end of the injector.

10 Step 14 The complete O-ring stack should look like the picture below. Using supplied grease packet, apply a small amount of grease to each injector O-ring and evenly coat completely around the each O-ring. You do not need to use a lot of grease! This should be a thin coating of grease to ensure it will not result in clogging your injector port.

11 Step 15 You are now ready to insert the injector into your new fuel rails. Your new fuel rails are identified with a single asterisk mark on the end. Step 16 With a gentle pushing pressure, insert the injectors into the new fuel rail. Please make sure that the injector wire plug housing is oriented at a right angle to the bottom of fuel rail as shown in the illustration below.

12 Step 17 With a gentle pushing pressure, insert the injectors and fuel rail assembly back into the throttle body.

13 Step 18 Reinstall the Allen cap screws that were set aside. Please screw them in by hand and do not use any power tools to start or finish the process. Step 19 With the Allen wrench, tighten the Allen cap screws. You want the fitment to be snug plus ¼ turn. DO NOT OVER TIGHTEN as you may damage or strip the throttle body. Step 20 Repeat steps 2 19 for the left side of the Summit MAX-efi 500.

14 Step 21 Next, seal and replace the end caps on your replacement fuel rails. End caps go into the fuel rail on opposite side from throttle linkage. You will need 2 of the 9/16 D x.063 nylon seals (these are the thinner seals provided in the kit) and the 2 end caps. Place one nylon seal onto the treaded portion of the end cap and hand thread the end caps onto both fuel rails on the opposite side of the throttle body linkage. Step 22 Using your adjustable wrench, tighten the end caps until they are snug plus ¼ turn. DO NOT OVER TIGHTEN as you may damage the fuel rail or strip the threads.

15 Step 23 Next, reinstall and seal the fuel delivery banjos on the opposite side of your replacement fuel rails using the replacement banjo fittings provided. You will need 2 of the 9/16 D x.156 nylon seals and 2 of the 9/16 D x.063 nylon seals. These are the thicker seals provided in the kit. Additionally, you will need your 2 new banjo fittings. Step 24 Place one 9/16 x.063 nylon seal (thin seal) on the banjo fitting. Insert banjo fitting and thin seal into fuel crossover line. Place 9/16 x.156 (thick) nylon seal onto banjo fitting/crossover assembly. Step 25 Repeat Step 24 to seal and connect the opposite side of crossover fuel line.

16 Step 26 Hand thread both banjo fittings onto fuel rails. This is done on the linkage side of the throttle body. Note, the fuel inlet banjo will be furthest from the linkage and must point downward. Step 27 Using 11/16 open end wrench, tighten the banjo fittings until they are snug plus ¼ turn. DO NOT OVER TIGHTEN as you may damage the fuel rail or strip the threads. Your fuel rail update and this recall are now complete. Confirm replacement fuel rails, banjos and cross over fuel line are assembled as indicated in picture below. If you removed throttle body from your engine, please refer to your installation instructions you received with your MAX-efi 500.

17 Summit Racing Equipment and FiTech are offering a $ Summit gift card, as a thank you for continuing to support our products. Limit 1 gift card per customer/shop performed recall. Gift cards are not assignable, carry no cash value and not available where prohibited. Offer conditioned upon proof of original Max-efi500 purchase and picture establishing old fuel rails have been destroyed. Using safety glasses, you can easily break off the mounting tabs by hitting them with a hammer. photo to PSN@FiTechefi.com with your contact information for verification of original purchase and records matching. Summit Racing Equipment and FiTech apologize for any inconvenience this voluntary recall may cause; however, our overriding concerns are your safety and satisfaction with the products we sell.