Repair Procedures: Removal

WARNING: In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")

CAUTION: When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur.
Delete the code with the GDS after completion of "Release Residual Pressure in Fuel Line" work.
Disconnect the fuel pressure control valve connector (A)
Disconnect the fuel feed tube quick-connector (B) with a clip removing tool.

Fig 1: Identifying Fuel Feed Tube Quick-Connector
Courtesy of KIA MOTORS AMERICA, INC.

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, it can cause a fuel leak due to bad connection and could result in a fire.

Fig 2: Identifying Clip Removing Tool
Courtesy of KIA MOTORS AMERICA, INC.
Remove the Intake Manifold.
(Refer to Engine Mechanical System - "INTAKE MANIFOLD ")
Remove the high pressure fuel pipe.
1. Remove the bracket mounting bolt (A).
  
  Fig 3: Identifying Bracket Mounting Bolt
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the high pressure pipe bracket bolt (A).
3. Remove the high pressure pipe flange nuts (B).
  
  Fig 4: Identifying High Pressure Pipe Flange Nuts And Bracket Bolt
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Remove the installation high pressure fuel pipe flange nut from the high pressure fuel pipe with the special service tool [SST No.: 09314-3V100].
Remove the mounting bolts (A), and then remove the high pressure fuel pump from the cylinder head assembly.
CAUTION: Unscrew in turn the two bolts in small step (0.5 turns). In case of fully unscrewing one of the two bolts with the other bolt installed, the housing surface of the cylinder head may be broken because of tension of the pump spring.

Fig 5: Identifying High Pressure Fuel Pump Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.