Kia Sportage 2005-06

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine cover.
  6.  
  7. Disconnect the TPS (Throttle Position Sensor) connector and ISA (Idle Speed Actuator) connector.
  8.  
  9. Disconnect the PCV (Positive Crankcase Ventilation) hose and breather hose.
  10.  
  11. Remove the accelerator cable.
  12.  
  13. Remove the delivery pipe.
  14.  
  15. Remove the clips and injectors.
  16.  
  17. Installation is in the reverse order of removal with new gasket. Coat the new O-rings with clean engine oil. Torque the delivery pipe bolts to 7-11 ft. lbs. (10-15 Nm).
  18.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove air cleaner hose.
  8.  
  9. Disconnect the accelerator cable. 
  10.  
  11. Disconnect the TPS connector (A). 
  12.  
  13. Disconnect the ISA connector (B). 
  14.  
  15. Disconnect the VIS actuator connector (C). 
  16.  
  17. Disconnect the injector connector (D). 
  18.  
  19. Disconnect the PCSV connector (E). 
  20.  
  21. Disconnect the PCSV hose. 
  22.  
  23. Disconnect the brake booster vacuum hose. 
  24.  
  25. Disconnect the PCV hose. 
  26.  
  27. Disconnect the IAT sensor connector. 
  28.  
  29. Disconnect the VIS actuator connector. 
  30.  
  31. Disconnect the ground cable from the surge tank assembly. 
  32.  
  33. Remove the surge tank stay. 
  34.  
  35. Remove the surge tank assembly. 
  36.  
  37. Remove the clips and injectors.
  38.  

To install:

  1. Install the injector assembly. Coat the new O-rings with clean engine oil. Torque the delivery pipe bolts to 7-11 ft. lbs. (10-15 Nm).
  2.  
  3. Install the surge tank assembly.
  4.  
  5. Install the surge tank assembly. Tighten to 11-15 ft. lbs. (15-20 Nm).
  6.  
  7. Install the surge tank stay. Tighten to 11-15 ft. lbs. (15-20 Nm).
  8.  
  9. Install the ground cable. 
  10.  
  11. Connect the VIS actuator connector. 
  12.  
  13. Connect the IAT sensor connector. 
  14.  
  15. Connect the PCV hose. 
  16.  
  17. Connect the brake booster vacuum hose. 
  18.  
  19. Connect the PCSV hose. 
  20.  
  21. Connect the PCSV connector. 
  22.  
  23. Connect the injector connector. 
  24.  
  25. Connect the VIS actuator connector. 
  26.  
  27. Connect the ISA connector. 
  28.  
  29. Connect the TPS connector. 
  30.  
  31. Connect the actuator cable. 
  32.  
  33. Install the air cleaner hose.
  34.  
  35. Install the engine cover.
  36.  
  37. Connect the negative battery cable.
  38.  

 
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