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Home >> Kia >> 2020 >> Optima EX >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Control System - 1.6L (Except HEV) >> Fuel Pressure Control Valve (FPCV) >> Repair Procedures >> Removal
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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.
  1. Release the residual pressure in fuel line.

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

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

    (Refer to Engine Electrical System - "BATTERY ")

  4. Remove the air cleaner and the air intake hose.

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

  5. Remove the engine wiring.
    1. Disconnect the OCV connector (A) and EWGA extension connector (B).
      G12915483Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the engine wiring mounting bolts, and then remove the engine wiring harness (A).
    G12915484Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the fuel feed tube quick-connector (A).
    G12915485Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Open the clamp cover (A) before disconnect the quick connector. (If the clip is applied)
    G12915486Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION: When removing the quick-connector 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.
    G12915487Courtesy of KIA MOTORS AMERICA, INC.
  7. 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 Flange Nut: 

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

      G12915488Courtesy 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 Flange Nut: 

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

      G12915489Courtesy of KIA MOTORS AMERICA, INC.
      G12915490Courtesy of KIA MOTORS AMERICA, INC.
    3. Disconnect the engine coolant temperature sensor connector (A).
      G12915491Courtesy 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)

      G12915492Courtesy of KIA MOTORS AMERICA, INC.
    5. Remove the high pressure fuel pipe (A).
      G12915493Courtesy of KIA MOTORS AMERICA, INC.
  8. 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.
    G12915494Courtesy of KIA MOTORS AMERICA, INC.
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