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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. Before repairing the high pressure system, be sure to release the residual pressure in fuel line as step  2 in below procedure.
  1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  2. Release the residual pressure in fuel line (Refer to the Fuel Delivery System - REPAIR PROCEDURES - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ").
    CAUTION: When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after completion of "RELEASE RESIDUAL PRESSURE IN FUEL LINE " work.
  3. Remove the intake manifold (Refer to "INTAKE AND EXHAUST SYSTEM ").
  4. Disconnect the injector connectors (A) and the rail pressure sensor connector (B).
  5. Remove the high pressure fuel pipe (C).
  6. Remove the engine oil gauge.
  7. Remove the installation bolt (D), and then remove the delivery pipe and injector assembly from the engine.
Fig 1: Disconnecting Injector Connectors
G11845330Courtesy of KIA MOTORS AMERICA, INC.
Fig 2: Removing High Pressure Fuel Pipe
G11845331Courtesy of KIA MOTORS AMERICA, INC.
Fig 3: Removing Delivery Pipe And Injector Assembly From Engine
G11845332Courtesy of KIA MOTORS AMERICA, INC.