Kia Carens: Fuel Delivery System / High Pressure Fuel Pump Repair procedures

Kia Carens RP (2013-2018) Service Manual / Engine Control / Fuel System / Fuel Delivery System / High Pressure Fuel Pump Repair procedures

Removal

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.

1.	Turn the ignition switch OFF and disconnect the battery negative (-) cable.

Release the residual pressure in fuel line. (Refer to Fuel Delivery System - “Release Residual Pressure in Fuel Line”)

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 air cleaner and the air intake hose. (Refer to Engine Mechanical System - “Intake Manifold”)

4.	Disconnect the fuel pressure regulator valve connector (A).

5.	Disconnect the fuel feed tube quick-connector (B).

Remove the high pressure fuel pipe.

(1)	Remove the installation nut (A) from the high pressure fuel pump with the special service tool [SST No.: 09314-3Q100 or 09314-27130]

(2)	Remove the installation nut (B) from the delivery pipe with the special service tool [SST No.: 09314-3Q100 or 09314-27130]

(3)	Disconnect the engine coolant temperature sensor connector.

(4)	Remove the function block (C), and then remove the high pressure fuel pipe.

Remove the installation bolts (D), and then remove the high pressure fuel pump from the cylinder head assembly.

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.

Installation

•	Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.

•	Be careful to be free from foreign materials when assembling.

•	Do not reuse the used bolt.

•	Do not reuse the used high pressure fuel pipe.

•	When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5 turns) after tightening them with hand-screwed torque.

•	Install the component with the specified torques.

•

First hand-tighten the fasteners fully until they are not fastened any more in orderto have them inserted in place and then completely tighten to the specified torque using a torque wrench.

If not tightening the bolts or nuts in a straight line with the mating bolt holes or fittings, it may cause a fuelleak due to broken threads.

•	Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

•	Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove on the location where the protrusion (C) is installed.

Installation is reverse of removal.

Use the special service tool [SST No.: 09314-3Q100 or 09314-27130] to install the high pressure fuel pipe.

High pressure fuel pump installation bolt:

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

High pressure fuel pipe installation nut:

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

High pressure fuel pipe function block installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Delivery Pipe Repair procedures

Removal In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and inject ...

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