So, I've been running the portfueler for a while now and everything was fine. Then, I started blowing the fuse that I had inline for the Additional Injector Controller once in a while. Now I can't even put a fuse in, it blows instantly. I sent the unit to split sec to be tested, and they said everything was working like it's supposed to. After reinstalling it, same problem. So, I unplugged each injector one by one, and I finally made some progress. If the cyl. #1 injector is unplugged, it doesn't blow the fuse. No matter which inj. clip is on which injector, if #1 is unplugged, the fuse wont blow. So I called Mark back at Split Sec, and he has never heard of this problem. He told me that even if I had 4 shorted injectors, It shouldn't blow the fuse because the car is off and the AIC isn't even sending a signal to fire any of the injectors. If I have the #1 inj. connected, and I touch the power wire to batt. It instantly gets very hot. I think my inj. is either stuck open or fried, but according to split sec, that is impossible.

Any suggestions, this is my daily driver. I do have a truck, but the 5.0 sucks the gas.

Also, is there an easy way to remove the secondary injectors without removing the intake manifold?

Thanks in advance, this is killing me.
(I just started to get a decent tune going, Go figure)

I don’t have a portfueler but ill give this a try..

I would start by checking the wires, making a schematic in express PCB and showing us how you wired up your portfueler wouldn’t hurt (including what fuses you have and where). Start by making sure your fuses aren’t exceeding the current there rated at. Check for unintentional groundings (bare wire touching the frame of the car) I think it’s more on your wiring you need to look at then the portfueler. Check the injector with an ohm meter and to see if it’s any good.

And for your last answer – only if you want to plug the injector ports, if not then you have to remove the manifold...

Like Mark said, check the injector with your ohmmeter to verify it's not way out of whack.

I'd suspect your wiring first and foremost, though.

Thats what I originally thought, until I switched the inj. clips around, and it didn't matter which clips were connected to the remaining 3 injectors. But the minute I hooked up the # 1 inj, the fuse would blow. And, split sec ran the unit on a set of there inj. for over 20 min. and never blew a fuse.

The wiring is very simple. There is a power, ground, and tach signal going into the AIC, and a pos. and neg. coming out and going to each injector. That's it. I have the pos. connected via a fuse tap in the engine bay with a 20 amp fuse. I have already inspected all of the wiring and there is no visable damage to the naked eye. I'll test the resistance of each inj. and see if that #1 is f'd up.

Well, after several hours of messing with the portfueler, I have found the problem. Somehow, the injector is sending power through the internal coil, which somehow transfers to the metal injector body. Since the manifold is grounded, that makes a direct power to ground circuit. If I hold the injector up in the fuel rail, the fuse doesn't blow, as soon as I pressurize the fuel system, it pushes the injector against the manifold, and blows the fuse. I guess I am the only one this has ever happened to, because the guy at accel and split sec have never heard of anyone with this problem. WEIRD!