A few members found this helpful so I figured I should post it up in the Tech Articles for future use. It is pretty straight forward and once you've done it once, you'll say "That was it!?". So this will basically guide those of you looking to replace the injector O-rings or replace fuel injectors. This is not a good guide for installing an aftermarket fuel rail or installing the longer High Impedance Injectors such as FIC 2150's.
Also, as a safety precaution: Open the gas cap to vent out excess pressure, let the car sit for a good 30 minutes before removing fuel lines, and be prepared for gasoline to spurt out of the fuel system. Rags, safety glasses, and most importantly a fire extinguisher are good thing to have around when working with anything related to fuel.
Here's the view from the engine bay. Red is your fuel rail, yellow is the fuel feed, and blue is the fuel return. The three bolts on top of this rail will need to be taken out, the fuel feed will need to be taken off (2 bolts), and the fuel return will need to be taken off (2 bolts). I'm not sure what size/kind of bolts they are since mine have been aftermarket Allen Head fasteners since day one. I believe the fuel rail bolts are 12mm or 13mm. You will also need to remove the PCV hose which goes to the valve cover right over the fuel rail on the left-hand side.
Once you get the fuel rail unbolted, unplug the fuel injectors. Circled in red is one of the fuel injectors, you will have 4 total. Circled in yellow are the connectors. You will have 1 for every injector. You can't put them on in the wrong direction because they are keyed, but you can put them on in the wrong order. I would suggest labeling them with tape and a marker. Start from the timing belt and label them 1, 2, 3, 4. Also be very careful not to lose the little plastic spacers that go in the same spot as the fuel rail bolts. They are essential so if you lose one and can't find it, replace it with a new one. I have personally used silicone sealer to secure the black plastic spacers to the fuel rail. This way there is no chance of loosing them in the engine bay.
These are you fuel injectors. Circled in red is the lower seals. They are usually in the port where the fuel injector sits. Sometimes they stick to the injector, but if you don't see any on the injector check the port where the injector goes. I would advice replacing these as they can cause boost leaks. Circled in yellow is the upper O-rings. You should always replace these while you have the injectors out. Even a slightly damaged injector O-ring can spew fuel like a faucet. Remember, your car has over 40psi of fuel pressure behind those seals so it's important they work properly.
For reinstall you just do everything backwards. One word of advice though is to grease (yes with wheel bearing grease, axle grease, etc.) the O-rings before installing the fuel injectors. This will make sure the O-rings don't fold or twist when installing them. Grease both the upper and lower. Then just pop the injectors back in the rail, guide the injectors back into their port, make sure you have all your black plastic spacers in place, and bolt the rail down. Once it's all back together, plug your fuel injectors back in (in the correct order), and install the fuel feed & return. The car may take a few extra cranks to start for the first time, but if you smell fuel or the car idles rough, then something isn't hooked up properly. It also wouldn't hurt to replace the fuel feed & return O-rings, but I have personally never had a problem reusing them so long as they were greased before install.
Here's the link for upper O-rings. Just ask about the lower one's and they should be able to help you out.
Fel-Pro ES70600 - Fuel Injection O-Ring Set | O'Reilly Auto Parts
Also, as a safety precaution: Open the gas cap to vent out excess pressure, let the car sit for a good 30 minutes before removing fuel lines, and be prepared for gasoline to spurt out of the fuel system. Rags, safety glasses, and most importantly a fire extinguisher are good thing to have around when working with anything related to fuel.
Here's the view from the engine bay. Red is your fuel rail, yellow is the fuel feed, and blue is the fuel return. The three bolts on top of this rail will need to be taken out, the fuel feed will need to be taken off (2 bolts), and the fuel return will need to be taken off (2 bolts). I'm not sure what size/kind of bolts they are since mine have been aftermarket Allen Head fasteners since day one. I believe the fuel rail bolts are 12mm or 13mm. You will also need to remove the PCV hose which goes to the valve cover right over the fuel rail on the left-hand side.
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Once you get the fuel rail unbolted, unplug the fuel injectors. Circled in red is one of the fuel injectors, you will have 4 total. Circled in yellow are the connectors. You will have 1 for every injector. You can't put them on in the wrong direction because they are keyed, but you can put them on in the wrong order. I would suggest labeling them with tape and a marker. Start from the timing belt and label them 1, 2, 3, 4. Also be very careful not to lose the little plastic spacers that go in the same spot as the fuel rail bolts. They are essential so if you lose one and can't find it, replace it with a new one. I have personally used silicone sealer to secure the black plastic spacers to the fuel rail. This way there is no chance of loosing them in the engine bay.
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These are you fuel injectors. Circled in red is the lower seals. They are usually in the port where the fuel injector sits. Sometimes they stick to the injector, but if you don't see any on the injector check the port where the injector goes. I would advice replacing these as they can cause boost leaks. Circled in yellow is the upper O-rings. You should always replace these while you have the injectors out. Even a slightly damaged injector O-ring can spew fuel like a faucet. Remember, your car has over 40psi of fuel pressure behind those seals so it's important they work properly.
You must be logged in to view this image or video.
For reinstall you just do everything backwards. One word of advice though is to grease (yes with wheel bearing grease, axle grease, etc.) the O-rings before installing the fuel injectors. This will make sure the O-rings don't fold or twist when installing them. Grease both the upper and lower. Then just pop the injectors back in the rail, guide the injectors back into their port, make sure you have all your black plastic spacers in place, and bolt the rail down. Once it's all back together, plug your fuel injectors back in (in the correct order), and install the fuel feed & return. The car may take a few extra cranks to start for the first time, but if you smell fuel or the car idles rough, then something isn't hooked up properly. It also wouldn't hurt to replace the fuel feed & return O-rings, but I have personally never had a problem reusing them so long as they were greased before install.
Here's the link for upper O-rings. Just ask about the lower one's and they should be able to help you out.
Fel-Pro ES70600 - Fuel Injection O-Ring Set | O'Reilly Auto Parts
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