I30 1996-1997

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



  1. Release the fuel system pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been turned OFF. Properly relieve the fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Disconnect the negative battery cable and drain the cooling system.
  4.  
  5. Remove the throttle body coolant hoses.
  6.  
  7. Label and disconnect the electrical connectors from the throttle position sensor.
  8.  
  9. Label and disconnect the hoses from the throttle body, the EGR valve, intake manifold collector, IAC valve, and the fuel pressure regulator.
  10.  
  11. Disconnect the canister purge hose and blow-by hose.
  12.  
  13. Disconnect the EGR guide tube.
  14.  
  15. Disconnect the accelerator cable from the throttle body.
  16.  
  17. Remove the intake manifold collector support brackets.
  18.  
  19. Disconnect the right side electrical connectors from the ignition coils.
  20.  
  21. If necessary, disconnect the electrical connector from the crank angle sensor and the power transistor.
  22.  
  23. Remove the intake manifold collector-to-intake manifold bolts/nuts and remove the intake manifold collector.
  24.  
  25. Remove the fuel injector assembly by performing the following procedures:
    1. Disconnect the electrical connectors from the fuel injectors.
    2.  
    3. Disconnect the fuel lines from the fuel injector assembly.
    4.  
    5. Remove the fuel rail-to-cylinder head bolts.
    6.  
    7. Remove the fuel rail assembly from the engine.
    8.  

  26.  
  27. To remove the fuel injector from the fuel rail, remove the fuel injector-to-fuel rail bolts and remove the fuel injector from the fuel rail; discard the O-rings.
  28.  

To install:

  1. To install the fuel injector to the fuel rail, perform the following procedures:
    1. Install new O-rings onto the fuel injector.
    2.  
    3. Wet the new O-rings with fuel and press the injector into the fuel rail.
    4.  
    5. Install the bolts and tighten the fuel injector retainer to 27-33 inch lbs. (2.9-3.8 Nm).
    6.  

  2.  
  3. Clean the gasket mounting surfaces.
  4.  
  5. Install the fuel injector assembly by performing the following procedures:
    1. Install the fuel rail assembly to the engine.
    2.  
    3. Install the fuel rail-to-cylinder head bolts and torque the bolts to 15-20 ft. lbs. (21-26 Nm) in two progressive steps.
    4.  
    5. Connect the fuel lines to the fuel injector assembly.
    6.  
    7. Connect the electrical connectors to the fuel injectors.
    8.  

  6.  
  7. Using a new gasket, install the intake manifold collector and torque the intake manifold collector-to-intake manifold bolts/nuts to 13-16 ft. lbs. (18-22 Nm).
  8.  
  9. Install the intake manifold collector supports and torque the bolts to 14-18 ft. lbs. (20-25 Nm).
  10.  
  11. Connect the electrical connectors to the ignition coils and tighten the mounting bolts to 27-33 inch lbs. (2.9-3.8 Nm)
  12.  
  13. Connect the accelerator cable to the throttle body.
  14.  
  15. Connect the EGR guide tube and tighten the bolts to 15-20 ft. lbs. (21-26 Nm) in two progressive steps.
  16.  
  17. Connect the canister purge hose and blow-by hose.
  18.  
  19. Connect the hoses to the throttle body, EGR valve, intake manifold collector, IAC valve, and the fuel pressure regulator.
  20.  
  21. If disconnected, connect the electrical connectors to the crank angle sensor and the power transistor.
  22.  
  23. Connect the electrical connectors to the throttle position sensor.
  24.  
  25. Connect the throttle body coolant hoses.
  26.  
  27. Refill the cooling system and connect the negative battery cable.
  28.  
  29. Start the engine, bleed cooling system, and check for leaks.
  30.  

 
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