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1999 Acura Integra: Intake and Fuel System Upgrade A turbochcharged Integra gets a further horsepower injection with a modified intake manifold and fuel-system tweaks. From "Tricked Out" episode DTRK-409

(Continued from page 2)

Modify Intake Manifold Components and Install New Fuel Rail

In the next phase of the project, Andrew begins to modify the components of the new intake manifold, which has a bigger opening than the factory throttle body. The new components will allow for smoother airflow and enhanced engine performance.

Removing the stock fuel rail

Installing the performance fuel rail

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Materials and tools needed for this phase of the project:

high-performance intake manifold
rotary tool
fresh gaskets
high-flow fuel rail
standard shop tools

The stock fuel rail

The performance fuel rail

	Figure G
	Figure I
	Figure H

Modify Intake Manifold Components

• Using the gasket from the new intake manifold as a template (figure G), trace the opening onto the throttle body.

• Be sure to protect the parts your not using by getting them out of the way.

• Using the rotary tool, carefully round off the edge, working slowly to make a nice even cut (figure H).

• Once I have worked all of the way around the opening, the whole thing needs to be cleaned so that none of the metal shavings go into the engine.

• Use a new gasket for a tight seal between the ported throttle body and the new high-flow intake manifold (figure I).

Install New Fuel Rail

Now that the air handling has been taken care of, it's time to work on getting more fuel into the cylinders. To do this, Andrew installs a high-flow fuel rail.

• Pull the injectors out of the old manifold, swap them over and install the fuel rail.
  

  Figure J

• Remove the three nuts connected to the factory manifold studs and lift the fuel rail off of the injectors first before carefully removing the injectors from the stock manifold.

• The old O-rings and injector seats won't seal as well because they've been compressed and brought up to temperature, so replace them with the new rings and seats, using petroleum jelly to make the process easier.

• Insert the injectors into the manifold, place the new fuel rail on top of the injectors (figure J), making sure to line them up correctly, and tighten the whole thing down.

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