Kia Forte: Engine Control / Fuel System / Fuel Delivery System

Kia Forte 2019-2020 (BD) Service Manual / Engine Control / Fuel System / Fuel Delivery System

Components and components location
Components Location
Fuel Tank & Filler-Neck Assembly

1. Fuel Tank
2. Fuel Pump
3. Fuel Pump Plate Cover
4. Fuel Filler Hose
5. Leveling Tube
6. Vapor port [Fuel pump (Canister) → Intake Manifold]
7. Vapor Hose [Fuel pump (Canister) → Atmosphere]
8. Filler-Neck Assembly

Fuel Pump

1. Head Assembly
2. Fuel Pressure Regulator
3. Fuel Filter
4. Fuel Pump Motor
5. Fre-Filter
6. Reservoir Cup
7. Fuel Sender
8. Fuel Pump Motor & Fuel Sender Connector
9. Vapor Port [Fuel pump ↔ Canister]
10. Fuel Feed Port

[High Pressure Fuel Line]

1. High Pressure Fuel Pump
2. High Pressure Fuel Pipe
3. Delivery Pipe
4. Injector

  

Whenever the high pressure fuel pump, fuel pipe, deliverypipe, or injector is removed immediately after shutting offthe engine, an injury may be caused by the release ofhighly pressurized fuel. Release the residual pressure inthe high pressure fuel line by referring to the "Residualfuel pressure release procedure" below before removingany high pressure fuel system components.

Schematic diagrams
Schematic Diagrams

Fuel pressure test (low pressure system)
Fuel Pressure Test (Low pressure system)
1.

Release the residual pressure in fuel line.

(Refer to the Fuel Delivery System - Inspection - "Release Residual Pressure in Fuel Line").

  

When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the KDS/GDS after completion of “Release Residual Pressure in Fuel Line” work.

2.

Install the Special Service Tool (SST).

(1)

Disconnect the fuel feed tube from the delivery pipe.

  

There may be some residual pressure even after “Release Residual Pressure in Fuel Line” work, so cover the hose connection with a shop towel to prevent residual fuel from spilling out before disconnecting any fuel connection.

(2)

Install the special service tool for measuring the fuel pressure in between the fuel feed tube and the fuel delivery pipe (Refer to the figure below).

For 09353-02100

For 0K353-D4100

3.

Inspect fuel leakage on connections among the low fuel feed tube, the low pressure inlet of high pressure fuel pump, and the SST components with IG ON.

4.

Measure Fuel Pressure.

(1)

Start the engine and measure the fuel pressure at idle.

Fuel Pressure: Over 500 kPa (Over 5.0 bar, Over 5.09 kgf/cm², Over 72.51 psi)

  

If the fuel pressure differs from the standard value, repair or replace the related part (Refer to the table below).

Fuel
Pressure
Cause
Related Part
Too Low
Fuel filter clogged
Fuel Filter
Fuel leakage
Fuel Pressure Regulator
Too High
Fuel pressure regulator stuck
Fuel Pressure Regulator

(2)

Stop the engine, and then check for the change in the fuel pressure gauge reading.

Standard Value: The gauge reading should hold for about 5 minutes after the engine stops

  

If the gauge reading should not be held, repair or replace the related part (Refer to the table below).

Fuel Pressure
(After Engine Stops)
Cause
Related
Part
Fuel Pressure Drops Slowly
Leakage on injector
Injector
Fuel Pressure Drops Immediately
Check valve of fuel pump stuck open
Fuel Pump

(3)

Turn the ignition switch OFF.

5.

Release the residual pressure in fuel line.

(Refer to the Fuel Delivery System - Inspection - "Release Residual Pressure in Fuel Line").

  

When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the KDS/GDS after completion of “Release Residual Pressure in Fuel Line” work.

6.

Test End

(1)

Remove the Special Service Tool (SST) from the low pressure fuel feed tube and the low pressure inlet of high pressure fuel pump.

(2)

Connect the low pressure fuel feed tube and the low pressure inlet of high pressure fuel pump.

Release residual pressure in fuel line
Release Residual Pressure in Fuel Line
  

There may be some residual pressure even after “Release Residual Pressure in Fuel Line” work, so cover the hose connection with a shop towel to prevent residual fuel from spilling out before disconnecting any fuel connection.

1.

Turn the ignition switch OFF and disconnect the battery (-) terminal.

2.

Remove the fuel pump fuse (A).

  

When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the KDS after completion of “Release Residual Pressure in Fuel Line” work.

3.

Connect the battery negative (-) terminal.

4.

Start the engine and let idle.

5.

Turn the ignition switch OFF after the engine has stopped on its own.

6.

Disconnect the battery negative (-) terminal, and then install the fuel pump fuse (A).

7.

Connect the battery negative (-) terminal.

8.

Delete the Diagnostic Trouble Code (DTC) related the fuel pump fuse with the KDS.

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Fuel Tank
Repair procedures Removal and Installation 1. Release the residual pressure in the fuel line. (Refer the Fuel Delivery system - "Release Residual Pressure in Fuel ...

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