AEM High Volume Fuel Rail 25109BK User Manual

ADVANCED ENGINE MANAGEMENT INC. 
2205 126TH Street, Unit A Hawthorne, CA. 90250 
Phone: (310) 484-2322 Fax: (310) 484-0152 
www.aempower.com 
Instructions Part Number: 10-316
 
96-00 Honda Multi-Port Fuel Injected D-Series Hi-Flow Fuel Rail  
© Copyright 2001 
Some applications are legal in California for racing vehicles which may never be used on public highways 
 
 
HI-FLOW 
FUEL RAIL 
 
 
 
 
 
 
Installation Instructions for: 
Part Number 25-109 
96-00 Civic 
 
  

 
Congratulations!  You have just purchased the finest Hi-Flow Fuel Rail for your car at 
any price! The AEM Hi-Flow Fuel Rail is the result of extensive development on a wide 
variety of cars. It is the most advanced Hi-Flow Fuel Rail on the market and is 
specifically engineered for its application. All AEM Hi-Flow Fuel Rails are CNC 
machined from 6061 T-6 billet aluminum and feature a ½-inch bore capable of flowing 
enough fuel to support most high-performance engines. This larger bore also dampens...

 
Read and understand these instructions BEFORE attempting to install 
this product. 
 
Note:  This fuel rail kit requires the removal and reinstallation of fuel system related components.  
If you are not familiar with the installation and/or the operation of these components then please 
refer this installation to a qualified professional. 
 
 
 
• Do not smoke while working on the fuel system. 
• Keep open flames and/or sparks away from your work area. 
• Be sure to relieve the fuel pressure while the...

  c) On models not equipped with a 6mm service bolt: 
i)  Use a box end wrench on the 12mm banjo bolt on top of the fuel filter. 
ii)  Place a rag or shop towel over the 12mm banjo bolt. 
iii)  Slowly loosen the 12mm banjo bolt one complete turn or until all pressure has been relieved. 
iv)  Torque the 12 mm banjo bolt to 25lb-ft. 
 
3)  Removal of stock fuel rail, injectors and fuel pressure regulator 
a)  Loosen and remove the nut holding the fuel inlet banjo fitting to the fuel rail. Be careful not to...

  j)  Inspect all seals, o-rings, and washers.  If any of these components look at all worn or damaged, 
then replace with genuine Honda parts. 
 
4)  Assembly of the AEM Fuel Rail 
a)  Lubricate the threads of the banjo adaptor fitting with a light coat of engine oil.  Place a –6 crush 
washer over the side with the larger threads and install the banjo adaptor fitting into the end of the 
AEM Fuel Rail that matches the placement of the fitting on the stock fuel rail. Be sure that the 
crush washer is...

  e)  Remove the old o-rings that are on top of the injectors. Coat the new o-rings, supplied with the kit, 
with clean engine oil and install them onto the injectors. 
f)  Insert the o-ring end of the injectors into the AEM Fuel Rail.  
g)  Coat the seal rings with clean engine oil and then install them into the intake manifold. 
h)  Install the fuel rail/injector assembly back onto the vehicle. Make sure that all of the seals and o-
rings are properly seated, and installed without damage.  
i)  Install...