Repair Procedures: Removal

WARNING: When removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, injury may be caused by leakage of high pressure fuel. For this reason, do not attempt any repairing immediately after engine stops.

Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")
Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
Remove the battery.
(Refer to Engine Electrical System - "BATTERY ")
Remove the air cleaner and the air intake hose.
(Refer to Engine Mechanical System - "AIR CLEANER ")
Remove the engine wiring.
1. Disconnect the OCV connector (A) and EWGA extension connector (B).
  
  Fig 1: Disconnecting OCV Connector And EWGA Extension Connector
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the engine wiring mounting bolts, and then remove the engine wiring harness (A).
  
  Fig 2: Removing Engine Wiring Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the fuel feed tube quick-connector (A).

Fig 3: Locating Fuel Feed Tube Quick-Connector
Courtesy of KIA MOTORS AMERICA, INC.

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

Fig 4: Locating Clamp Cover
Courtesy of KIA MOTORS AMERICA, INC.

WARNING: 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.

Fig 5: Removing Quick-Connector With Clip Removing Tool
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure fuel pipe.
1. Remove the flange nut (A) from the high pressure fuel pump with the special service tool [SST No.: 09314-3Q100 or 09314-27130]
  High pressure fuel pipe flang nut:
  
  26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb-ft)
  
  Fig 6: Locating Flange Nut From High Pressure Fuel Pump
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the flange nut (A) from the delivery pipe with the special service tool [SST No.: 09314-3Q100 or 09314-27130]
  High pressure fuel pipe flang nut:
  
  26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb.ft)
  
  Fig 7: Removing Flange Nut From Delivery Pipe With Special Service Tool (1 Of 2)
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 8: Removing Flange Nut From Delivery Pipe With Special Service Tool (2 Of 2)
  Courtesy of KIA MOTORS AMERICA, INC.
3. Disconnect the engine coolant temperature sensor connector (A).
  
  Fig 9: Disconnecting Engine Coolant Temperature Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the function block (A) after loosening the mounting bolt, and then remove the high pressure fuel pipe.
  High pressure fuel pipe function block mounting bolt:
  
  9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)
  
  Fig 10: Locating Function Block
  Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the high pressure fuel pipe (A).
Fig 11: Removing High Pressure Fuel Pipe
Courtesy of KIA MOTORS AMERICA, INC.
Remove the mounting bolts (A), and then remove the high pressure fuel pump from the cylinder head assembly.
High pressure fuel pump mounting bolt:

12.8 - 14.7 N.m (1.3 - 1.5 kgf.m, 9.4 - 10.9 lb.ft)

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 12: Removing High Pressure Fuel Pump From Cylinder Head Assembly
Courtesy of KIA MOTORS AMERICA, INC.