Hyundai Coupes/Sedans 1994-1998 Repair Guide

Fuel Charging Assembly

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REMOVAL & INSTALLATION



Except 3.0 (VIN T) Engine

See Figures 1



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Fig. Fig. 1: Fuel charging assembly and injectors-Scoupe

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
  6.  
  7. Disconnect the fuel return hose.
  8.  
  9. Disconnect the vacuum hose from the fuel pressure regulator.
  10.  
  11. Disconnect and remove the PCV hose.
  12.  
  13. Label and disconnect the electrical harnesses from each injector.
  14.  
  15. Remove the injector rail retaining bolts. Make sure the rubber mounting bushings do not get lost.
  16.  
  17. Lift the rail assembly up and away from the engine.
  18.  

To install:
  1. Install the fuel rail and injectors to the manifold. Make sure the rubber bushings are in place before tightening the mounting bolts. Tighten the retaining bolts to 7-11 ft. lbs. (11-13 Nm).
  2.  
  3. Connect the electrical harness to the injectors.
  4.  
  5. Install and connect the PCV hose.
  6.  
  7. Connect the fuel return hose.
  8.  
  9. Replace the O-ring, lightly lubricate it and connect the high pressure fuel line.
  10.  
  11. Connect the negative battery cable
  12.  
  13. Start the engine and check the entire system for proper operation and leaks.
  14.  

3.0L (VIN T) Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect all components from the air intake plenum and remove the plenum from the intake manifold. Discard the gaskets.
  8.  
  9. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
  10.  
  11. Disconnect the fuel return hose and remove the O-ring.
  12.  
  13. Disconnect the vacuum hose from the fuel pressure regulator. Remove the fuel pressure regulator and O-ring.
  14.  
  15. Disconnect the electrical connectors from each injector.
  16.  
  17. Remove the injector rail retaining bolts. Make sure the rubber mounting bushings do not get lost.
  18.  
  19. Lift the rail assemblies up and away from the engine.
  20.  

To install:
  1. Replace the insulators in the intake manifold, if equipped.
  2.  
  3. Install the fuel charging assemblies on the manifold. Make sure the rubber bushings are in place before tightening the mounting bolts. Tighten the retaining bolts to 5-8 ft. lbs. (7-11 Nm).
  4.  
  5. Install the fuel pipe with new gasket.
  6.  
  7. Connect the electrical harness to the injectors.
  8.  
  9. Connect the fuel return hose.
  10.  
  11. Replace the O-ring, lightly lubricate it and connect the high pressure fuel line.
  12.  
  13. Using new gaskets, install the intake plenum and all related items. Torque the plenum mounting bolts to 13 ft. lbs. (18 Nm).
  14.  
  15. Fill the cooling system.
  16.  
  17. Connect the negative battery cable
  18.  
  19. Start the engine and check the entire system for proper operation and leaks.
  20.  

 
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