Kia Picanto: Fuel System / High-Pressure Fuel Pump

1
Release the fuel line residual pressure. (Refer to Fuel System - "Release Fuel Line Residual Pressure")
2
Turn the ignition switch OFF and disconnect the negative (-) battery terminal.
3
Remove the air cleaner. (Refer to Engine Mechanical System - "Air Cleaner")
4
Disconnect the fuel pressure control valve (FPCV) connector (A) and the ignition coil connector (B).
5
Remove the bolts securing the engine control wiring harness (C).
6
Disconnect the quick-connect coupling of the fuel feed tube (A).

NOTEOpen the clip cover (A) before disconnecting the quick-connect fitting (if equipped with a clip).
When removing the quick-connect fitting using the clip removal tool (A), be careful not to damage the plastic clip (B). If the clip is damaged, a poor connection may cause a fuel leak.
7
Remove the purge control solenoid valve (PCSV). (Refer to Engine Control System – "Purge Control Solenoid Valve (PCSV)").
8
Remove the high-pressure fuel pump.
2. Remove the flange nut (A) from the delivery pipe using the special service tool [SST No.: 09314-3Q100 or 09314-27130].
3. Remove the mounting bolts (A) and remove the high-pressure fuel pump.

NOTE

Before installing the high-pressure fuel pump, rotate the crankshaft to set the roller tappet to the bottom position. Otherwise, the mounting bolts may break due to the pump spring tension.
Keep foreign material away from the components during assembly.
Do not reuse the bolt.
Do not reuse the high-pressure fuel line.
When tightening the high-pressure fuel pump mounting bolts, pre-tighten the bolts by hand, then fully tighten them in small steps (0.5 turn).
Install the component to the specified torque.
First, pre-tighten the bolts by hand until they are no longer loose in the holes, then fully tighten them to the specified torque with a torque wrench. If the bolts or nuts are not tightened in line with the bolt holes or fittings, the threads may strip and cause a fuel leak.
Note that internal damage may occur if the component is dropped. In this case, inspect it before use.
Apply engine oil to the O-ring (A) of the high-pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion (C) is installed.

Install in the reverse order of removal.
NOTEUse the special service tool [SST No.: 09314-3Q100 or 09314-27130] to install the high-pressure fuel pipe.

High pressure fuel pump