Repair Procedures: Removal

Low Pressure Fuel Line [High Pressure Fuel Pump ↔ Fuel Tank] 

1. Release the residual pressure in fuel line.

   (Refer to the Fuel Delivery System - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")

2. Turn ignition switch OFF and disconnect the battery negative (-) terminal.
3. Remove the battery.

   (Refer to Engine Electrical System - "BATTERY ")

4. Remove the air cleaner.

   (Refer to Engine Mechanical System - "AIR CLEANER ")

5. Disconnect the low pressure fuel line quick-connector (A) from the high pressure fuel pump.

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   NOTE: Open the clamp cover (B) before disconnect the quick connector. (If the clip is applied)

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   CAUTION: When removing the quick-connnector with the clip removing tool (A), be careful not to damage the plastic clip (B).
   If the clip is damaged, fuel line leak can be occurred due to a bad connection.

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6. Disconnect the vapor hose (A) which is connected from the PCSV.

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7. Remove the center muffler.

   (Refer to Engine Mechanical System - "MUFFLER ")

8. Remove the fuel tank.

   (Refer to Fuel Delivery System - "FUEL TANK ")

9. Remove the front sub frame.

   (Refer to Suspension System - "SUB FRAME ")

10. Remove the under cover [LH] (A) after loosening the mounting nuts.

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11. Remove the fuel line (A) after loosening the mounting bolts and bracket.

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High Pressure Fuel Line [High Pressure Fuel Pump ↔ Delivery Pipe] 

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1. Release the residual pressure in fuel line.

   (Refer to the Fuel Delivery System - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")

2. Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) terminal.
3. Remove the battery.

   (Refer to Engine Electrical System - "BATTERY ")

4. Remove the air cleaner.

   (Refer to Engine Mechanical System - "AIR CLEANER ")

5. Remove the high pressure pipe flange nut (A) in order of with the special service tool (B) [SST No. 09314 - 3Q100 or 09314 - 27130]

   High pressure fuel pipe flange nut  :

   26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb.ft)

   Courtesy of KIA MOTORS AMERICA, INC.

6. Remove the high pressure pipe flange nut (A) in order of with the special service tool (B) [SST No. 09314 - 3Q100 or 09314 - 27130]

   High pressure fuel pipe flange nut  :

   26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb.ft)

   Courtesy of KIA MOTORS AMERICA, INC.

   Courtesy of KIA MOTORS AMERICA, INC.

7. Remove the high pressure fuel pipe function block mounting bolt (A).

   High pressure fuel pipe function block mounting bolt  :

   9.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)

   Courtesy of KIA MOTORS AMERICA, INC.

8. Remove the high pressure fuel pipe (A).

   Courtesy of KIA MOTORS AMERICA, INC.