Repair Procedures: Removal

High Pressure Fuel Pipe (High Pressure Fuel Pipe ↔ Delivery Pipe) 

1. Release the residual pressure in fuel line.

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

2. Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
3. Remove the camshaft position sensor [bank1/intake]

   (Refer to Engine Control System - "CAMSHAFT POSITION SENSOR ")

4. Remove the intake manifold.

   (Refer to Engine Mechanical System - "INTAKE MANIFOLD ")

5. Remove the high pressure fuel pipe function block mounting bolt (A), 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 1: Locating High Pressure Fuel Pipe Function Block Mounting Bolt

   Courtesy of KIA MOTORS AMERICA, INC.
6. Remove the installation high pressure fuel pipe flange nut (A, B) from the high pressure fuel pipe with the special service tool [SST No.: 09314-3V100].

   High Pressure Fuel Pipe Flange Nut: 

   29.4 ~ 35.3 N.m (3.0 ~ 3.6 kgf.m, 21.7 ~ 26.0 lb-ft)

   Fig 2: Locating High Pressure Fuel Pipe Flange Nut

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7. Remove the high pressure fuel pipe.
   Fig 3: Locating High Pressure Fuel Pipe

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   Low Pressure Fuel Line (Fuel Tank ↔ Extension Fuel Line) 

1. Release the residual pressure in fuel line.

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

2. Remove the fuel tank.

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

3. Disconnect the low pressure fuel feed line quick-connector (A) and vapor line quick-connector (B).
4. Remove the low pressure fuel line (C).

Fig 4: Removing Low Pressure Fuel Line

Courtesy of KIA MOTORS AMERICA, INC.

Low Pressure Fuel Line (Extension Fuel Line ↔ Extension Fuel Line Side Engine Room) 

1. Release the residual pressure in fuel line.

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

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

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

4. Remove the low pressure fuel line mounting nuts (A).

   Low Pressure Fuel Line Mounting Nut: 

   3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   Fig 5: Locating Fuel Line Mounting Nuts

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5. Remove the fuel line fixing clip (A).
   Fig 6: Locating Fuel Line Fixing Clip

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6. Lift the vehicle.
7. Remove the front sub frame.

   (Refer to Suspension System - "FRONT SUSPENSION SYSTEM ")

8. Remove the fuel line from the vehicle.

Low Pressure Fuel Line (High Fuel Pump ↔ Extension Fuel Line Side Engine Room) 

1. Release the residual pressure in fuel line.

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

2. Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
3. Remove the low pressure fuel line mounting nuts (A).

   Low Pressure Fuel Line Mounting Nut: 

   3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   Fig 7: Locating Low Pressure Fuel Line Mounting Nuts

   Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect the connectors, and then remove the mounting bolts and remove the engine control wiring harness (A).
   Fig 8: Locating Engine Control Wiring Harness

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5. Remove the surge tank.

   (Refer to Engine Mechanical System - "SURGE TANK ")

6. Remove the low pressure fuel line mounting nuts (A).

   Low Pressure Fuel Line Mounting Nut: 

   3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   Fig 9: Locating Low Pressure Fuel Line Mounting Nuts

   Courtesy of KIA MOTORS AMERICA, INC.
7. Remove the low pressure fuel line mounting bolts, and then remove the low pressure fuel line (A).
   Fig 10: Locating Low Pressure Fuel Line Mounting Bolts (1 Of 2)

   Courtesy of KIA MOTORS AMERICA, INC.
   Fig 11: Locating Low Pressure Fuel Line Mounting Bolts (2 Of 2)

   Courtesy of KIA MOTORS AMERICA, INC.