Tucson 2006-2008

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure. Refer to Relieving Fuel System Pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air breather hose from the throttle body
     
    Throttle cable
     
    Engine coolant hose and throttle body
     
    Positive Crankcase Ventilation (PCV) valve and brake booster vacuum hose
     
    Vacuum hose connector
     
    Injector cover
     
    High pressure fuel hose
     
    Fuel injector harness connector
     
    Delivery pipe with the injectors and the pressure regulator as an assembly
     
    Injector from the delivery pipe
     

  6.  
  7. Remove and discard the injector O-ring and grommet.
  8.  

To install:

  1. Install a new grommet and O-ring.
  2.  
  3. Apply a coating of spindle oil or gasoline to the injector O-ring.
  4.  
  5. Install the injector into the delivery pipe while turning the injector left and right making sure the injector turns smoothly. If the injector does not turn smoothly, check for a jammed O-ring, remove the injector and reinsert it again.

    Click image to see an enlarged view

    Fig. Install the injector using a twisting motion

  6.  
  7. Install or connect the following:

    Delivery pipe (fuel rail) and injector assembly. Torque the bolts to 84-132 inch lbs. (10-15 Nm)
     
    Intake manifold stay and tighten the bolts to 13-18 ft. lbs. (18-25 Nm)
     
    Fuel injector harness connector
     
    High pressure fuel hose
     
    Injector cover
     
    Vacuum hose connector
     
    PCV valve and brake booster vacuum hose
     
    Throttle body and engine coolant hose
     
    Throttle cable
     
    Air breather hose from the throttle body
     
    Negative battery cable
     

  8.  
  9. Start the engine and check for leaks and for proper operation.
  10.  

 
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