Kia 3531023600 Injector Assembly-Fuel

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Relieve the fuel pressure. Disconnect the cable from the negative terminal of the battery. 1994 THROUGH 1997 MODELS Disconnect the Positive Crankcase Ventilation (PCV) valve from the valve cover, disconnect the PCV hose from the intake manifold and set them aside. On SOHC models, remove the hose clamps from the air valve, then remove the air valve from the intake plenum. Mark each injector electrical connector with a felt pen or paint. Disconnect each injector electrical connector using a small flat-blade screwdriver to release the connector lock lever while gently pulling the connector. Detach the two injector harness clips using needle-nose pliers, then set the harness aside. Disconnect the vacuum hose from the fuel pressure regulator. Disconnect the fuel lines from the fuel rail. Remove the fuel rail mounting bolts. Remove the fuel rail and the fuel injectors as a single assembly, being prepared for some fuel to drip out. Remove the fuel injectors from the fuel rail. If an injector seal sticks, gently wiggle the injector from side-to-side while pulling. Set the injectors aside in a clearly labeled storage container. Remove and discard the old injector grommets, O-rings, and insulators. Install new grommets, O-rings, and insulators whether reusing or replacing injectors. Coat new upper injector grommets and O-rings with clean engine oil, then insert each injector into its corresponding bore in the fuel rail. Coat each new injector lower insulator with clean engine oil and press it into its bore in the intake manifold. Installation is the reverse of removal. Tighten the fuel rail mounting bolts securely. Reconnect the cable to the negative battery terminal, then proceed. 1998 AND LATER FOUR-CYLINDER MODELS Disconnect the PCV crankcase ventilation hose from the valve cover and from the PCV pipe on the intake manifold. Remove the PCV hose, then disconnect the electrical connectors from the four fuel injectors. Disconnect the electrical connectors from the fuel injectors. Disconnect the fuel supply line quick-connect fitting from the fuel pulsation damper. Detach the accelerator cable bracket from the intake manifold. Remove the two fuel rail mounting bolts. Remove the fuel rail and the injectors as a single assembly. If any injectors stick in their bores, wiggle the fuel rail from side-to-side while pulling. Place the fuel rail/fuel injector assembly on a clean workbench, then remove the injectors from the fuel rail by removing the retainer clip and pulling the injector out. Remove and discard the old upper and lower O-rings from each injector, install new O-rings, and coat each with clean engine oil. Coat new upper injector O-rings with clean engine oil, then insert each injector into its corresponding bore in the fuel rail. Coat each new lower injector O-ring with clean engine oil and press it into that injector's bore in the intake manifold. Once the fuel rail assembly is in place, with all four injectors fully seated, install the fuel rail mounting bolts and tighten them securely. The remainder of the installation is the reverse of removal. Reconnect the cable to the negative battery terminal, then proceed. 2005 AND LATER V6 MODELS Remove the upper intake manifold. Remove the two bolts and disconnect the fuel supply line fitting from the fuel rail. Disconnect the electrical connectors from the fuel injectors. Remove the fuel rail mounting bolts. Remove the fuel rail and injectors as a single assembly. If any of the injectors stick in their bores, gently wiggle them from side-to-side while pulling. For the injector removal and installation procedure, repeat steps 22 through 25. Install the fuel rail and injectors as a single assembly and tighten the fuel rail mounting bolts securely. The remainder of the installation is the reverse of removal. ALL MODELS Turn the ignition switch to ON to activate the fuel pump and build up fuel pressure in the fuel lines and the fuel rail, but don't operate the starter yet. Repeat this two or three times, then check the fuel lines, fuel rails, and injectors for fuel leaks. Once confident that there are no leaks, start the engine and verify that the injectors are working and there are no fuel leaks.