Kia Forte: Fuel System / High Pressure Fuel Pump

Repair Procedures

Removal and Installation

1
Release the residual pressure in the fuel line.

(Refer to Fuel System - "Release Residual Pressure from Fuel Line")
2
Turn the ignition switch OFF and disconnect the negative (-) battery terminal.
3
Remove the air cleaner and the air intake hose.

(See Engine Mechanical System - "Air Cleaner")
4
Remove the battery.

(Refer to Engine Electrical System - Battery)
5
Disconnect the engine wiring connector and the wire harness clip.
6
Disconnect the quick-connector of the low pressure fuel line (A).

NOTE
Open the clip cover (A) before disconnecting the quick-connector. (If equipped with clip)

Caution
When removing the quick connector using the clip removal tool (A), be careful not to damage the plastic clip (B).

If the clamp is damaged, a fuel line leak may occur due to poor connection.
7
Remove the high pressure fuel tube.

(See Fuel System - "Fuel Line")
8
Remove the mounting bolts (A), then remove the high-pressure fuel pump from the cylinder head assembly.

High-pressure fuel pump mounting bolt:

12,8–14.7 N·m

Caution
Loosen the two bolts alternately in small increments (0.5 turn each). If one of the two bolts is fully removed while the other is still installed, the cylinder head surface may be damaged by the spring tension of the pump.
9
Install in the reverse order of removal.

NOTE
Use the special service tool [SST No.: 09314-3Q100 or 09314-27130] to install the high-pressure fuel line.
Warning
- Make sure the quick-connect coupling of the low-pressure fuel hose (A) is fully connected to the high-pressure fuel pump until it clicks into the locked position.
- After connecting, check the low-pressure fuel hose connection to the high-pressure fuel pump again by pulling on it.
- Be sure to tighten the high-pressure fuel pipe (B) to the specified torque.
- Since fuel leakage may cause a fire, carefully inspect all fuel line connections for leaks when starting the engine.
NOTE
- Before installing the high-pressure fuel pump, turn the crankshaft to set the roller tappet to the bottom-most position. Otherwise, the mounting bolts may break due to the spring tension of the pump.
- Take care that no foreign material enters during assembly.
- Do not reuse the bolt.
- Do not reuse the high-pressure fuel pipe.
- When tightening the high-pressure fuel pump mounting bolts, tighten the bolts alternately in small increments (0.5 turn each) after hand-tightening them to the specified torque.
- Install the component with the specified torque.
- First tighten the fasteners fully by hand until they are no longer loose enough to be inserted into position, then fully tighten them to the specified torque using a torque wrench.
  
  If bolts or nuts are not tightened straight with the bolt holes or fittings, thread damage may occur, which can cause fuel leakage.
- Note that internal damage may occur when the component is dropped. In this case, use it only after inspection.
- Apply engine oil to the O-ring (A) of the high-pressure fuel pump, the roller tappet (B), and the projection (C). Also apply engine oil to the groove where the projection (C) is installed.

High pressure fuel pump

Repair Procedures

Removal and Installation

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