AEM High Volume Fuel Rail 25130BK User Manual

							ADVANCED ENGINE MANAGEMENT INC. 
2205 126TH Street, Unit A Hawthorne, CA. 90250 
Phone: (310) 484-2322 Fax: (310) 484-0152 
Http://www.aempower.com 
Part Number: 10-335 
© 2002 Advanced Engine Management, Inc. 
 
 
 
 
 
 
 
 
 
 
 
HI-FLOW 
FUEL 
RAIL 
 
Installation Instructions for part number: 
 
25-130 
1989-1999 Mitsubishi Eclipse Turbo 4G63 
 
 
 
 
 
 
 
WARNING: 
The installation of this Fuel Rail Kit requires the removal and installation of fuel system 
components. Improper assembly/installation may result in bodily injury or property 
damage. If you are not qualified to perform this installation, please refer the installation 
to a professional. Read and understand these instructions before attempting to install 
this product.  
						

							! WARNING  Read and understand these instructions BEFORE
 attempting to install this product. 
 
• Do not smoke while working on the fuel system. 
• Keep open flames or sparks away from your work area. 
• Be sure to relieve fuel pressure before working on fuel system. 
 
1) Getting started 
a)  Make sure vehicle is parked on a level surface. 
b)  Set parking brake. 
c)  If engine has run within the past two hours let it cool down.
 
d)  Clean area around the fuel rail so that dirt cannot get into the engine. 
Note it is recommended to: 
•  Replace all cushion rings, seal rings and fuel injector insulators when fuel rail is disassembled. 
 
2)  Relieving fuel pressure 
a)  Disconnect the fuel pump harness connector. This connector is located at the rear of the fuel tank on 
1989-1994 Eclipses. On later model Eclipses, the fuel pump harness connector is located under the 
rear seat cushion. 
b)  Start the engine and allow it to stop by itself. Turn the ignition key to OFF. 
c)  Disconnect the negative (-) battery terminal. 
d)  Re-connect the fuel pump harness connector.
 
 
3)  Stock fuel rail and injector removal 
 
 
 
 
 
 
 
a) Remove the two bolts mounting the high-
pressure fuel inlet line to the fuel rail. Wrap a 
rag around the fitting and pull it clear of the 
fuel rail. b) Remove the two bolts mounting the fuel 
pressure regulator to the fuel rail. The rail will 
need to be repositioned before the regulator 
can be removed due to a lack of clearance 
with the cam cover. 
						

							 
 
 
 
 
 
 
 
 
e) Pull the fuel rail and injectors back from the intake manifold. The injectors should remain seated in the 
fuel rail. 
Notes:  
i) On some models the spark plug wires pass over the fuel rail and impede the removal of 
the fuel rail. On these models, it is necessary to remove the plastic spark plug cover and to 
pull the spark plug wires free. 
ii) It is not necessary to unplug the wire harness from the injectors. There should be 
enough space to pull the rail back and turn it upside down to gain access to the injectors. 
 
f) Remove the injectors from the rail and set the factory fuel rail aside. 
g) Remove the three plastic fuel rail spacers. These will not be reused with the AEM Fuel Rail Kit. 
 
4)  Assembly of the AEM Fuel Rail 
Warning: Improper assembly of the AEM fuel rail may result in leakage. Be sure to pressure test the 
fuel rail on the vehicle before starting the engine or test-driving. If there is any
 sign of leakage, the 
problem must be corrected before proceeding. 
a)  Refer to this section of the instructions upon initial assembly of the fuel rail, as well as when replacing 
the end adapters and o-ring seals.
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
c) Remove the fuel return line and vacuum 
line from the fuel pressure regulator. d) Remove the three fuel rail mounting bolts. 
The two outer bolts have throttle cable 
mounting brackets on them. Removing the 
throttle cable from the brackets and tucking it 
out of the way before removing the bolts may 
simplify removal/installation of the fuel rail.   
b) Make sure both ends of the fuel rail are 
clean and free of debris and burrs. c) Insert one 1-3024 o-ring into the inner 
groove. Make sure the o-ring is evenly seated 
in the groove.  
						

							 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
d) Insert another 1-3024 o-ring up against the 
first shoulder. Make sure the o-ring is seated 
evenly against the shoulder and is past the 
slots for the dowel pins. 
Make sure o-ring is 
past these slots. 
f) Gently insert the end adaptor into the fuel 
rail. Make sure the o-rings stay in place and 
are not torn. Insert two 1-2061 dowel pins into 
the dowel pin holes. 
Dowel 
pins 
g) Insert and tighten two 1-2062 screws into 
the dowel pin holes. Repeat steps b-g for the 
other side of the fuel rail. 
Inlet 
Adapter Install 
1/8” Pipe 
Plug 
Regulator 
Adapter 
f) Lightly lubricate the tip of the end adapter 
and the o-rings in the end of the fuel rail. Clean 
engine oil works well. 
e) Refer to this cut-away view for proper o-
ring installation. Warning: The o-rings MUST 
be properly seated as shown in this 
diagram. Improper installation may 
damage the o-rings and cause leakage. 
First o-ring goes 
in this groove 
Second o-ring goes 
against this shoulder 
O-rings MUST be past 
the dowel pin slot 
Lubricate 
						

							 
 
 
5)  Installation of the AEM Fuel Rail 
a)  Remove the old o-rings that are on top of the injectors. 
i)  Coat the new o-rings, supplied with the kit, with clean engine oil. 
ii)  Install the new o-rings onto the injectors. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
c)  Insert the o-ring ends of the injectors into the AEM Fuel Rail. 
d)  Install the fuel rail/injector assembly back onto the vehicle, using the three supplied aluminum standoffs 
in place of the factory plastic spacers. 
i.  Be careful to ensure that none of the seals get damaged. 
ii.  Make sure that all seals and o-rings are properly seated. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
f)  Replace the fuel return and vacuum lines on the fuel pressure regulator. 
g)  Mount the high-pressure fuel inlet line to the inlet adaptor on the AEM fuel rail, using the supplied M6 x 
8mm long bolts and split lock washers. 
b) Mount the factory fuel pressure regulator 
to the AEM fuel rail using the factory M6 
bolts and washers. The AEM fuel rail’s 
regulator flange has been designed to be 
used with both the 1989-1995 and the 1996-
1999 model year fuel pressure regulators. 
Note: Apply a light coat of engine oil to 
the re
gulator o-ring before installation.
e) Install and tighten the three fuel rail 
mounting bolts. Make sure to reinstall the 
two throttle cable brackets on the outer fuel 
rail bolts.  
						

							Note: Apply a light coat of engine oil to the inlet o-ring before installation. 
h) The AEM fuel rail comes with one additional fuel port. If you are running a wet nitrous oxide system, or a 
fuel pressure gauge, then this port may be used for the additional fuel supply.  If you are not in the need 
of an additional fuel source install the supplied 1/8” NPT plug.  
Note: When installing the tapered plug or any other tapered fitting into the AEM Fuel Rail, use only a 
lubricant or anti-seize on the threads.  Do not under any circumstances use liquid Teflon or 
Teflon tape as a sealant for any tapered plug or tapered fitting in any fuel system. 
j)  Replace the spark plug wires (if removed) and any hoses or vacuum lines that were disconnected 
during installation. 
 
6) Finishing Touches 
a)  Connect the negative battery terminal. 
b)  Turn the ignition switch to the on position for approximately two seconds.  Do not operate the starter.  
Then turn the ignition switch to the off position. 
c)  Repeat this procedure three times, and then check all components that were removed during installation 
for any signs of fuel leakage. 
i. Be sure to check the area around the fuel inlet fitting, the injectors, the regulator, 
and the 1/8” NPT plug.  If these items were not installed correctly, they may be 
prone to leakage. 
d) If there are signs of leakage you MUST
 correct the leak before proceeding. 
e)  If there are no signs of leakage, then start engine and again check for leaks. If there is any sign of 
leaking you MUST
 repair the leak before driving the vehicle.
 
 
 
 
 
 
 
 
 
 
 
 
 
Bill of Materials for Kit # 25-130 
Qty. Part Number  Description 
1  2-5130  Mitsubishi 4G63 Fuel Rail 
1  2-643  Mitsubishi Fuel Rail Inlet Adapter 
1  2-644  Mitsubishi Fuel Rail Reg. Adapter 
3  2-642  Mitsubishi Fuel Rail Standoff 
4  1-3024  O-Ring (BUNA 70) 
4  1-2061  3/32 x 5/8 Stainless Dowel Pin 
4  1-2062  5-40 x 1/4 Fillister Head Slotted 
1  1-121  1/8 Pipe Plug 
4  1-3008  O-Ring, Fuel Injector Seal 
2  1-2060  M6x1.0 8mm Long Bolt 
2 1-3025  M6 Spring Washer 
2  10-922S  Decal, AEM Large Silver 
1  2-5130  Mitsubishi 4G63 Fuel Rail 
1 10-335  Instructions 
 
 
 
 
 
 
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