Kia Forte: Fuel Delivery System / High Pressure Fuel Pump

Kia Forte 2019-2025 (BD) Service Manual / Engine Control / Fuel System / Fuel Delivery System / High Pressure Fuel Pump

Repair procedures

Removal & Installation

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

4.	Remove the battery. (Refer to Engine Electrical System - "Battery")

5.	Disconnect the engine wiring connector and harness clamp.

Disconnect the low pressure fuel line quick-connector (A).

Open the clamp cover (A) before disconnect the quick connector. (If the clip is applied)

When removing the quick-connnector 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.

7.	Remove the high pressure fuel pipe. (Refer to Fuel Delivery System - "Fuel Line")

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)

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.

Install in the reverse order of removal.

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

•	Be sure that the low pressure fuel hose quick-connector (A) is completely connected to the high pressure fuel pump by the locking sound.

•	Double-check the complete connection of the low pressure fuel hose to the high pressure fuel pump by pulling it after connecting.

•	Be sure to install the high pressure fuel pipe (B) to the specified torques.

•	Because fuel leak may cause fire, thoroughly inspect leakage of all fuel line connection parts at engine start condition.

•	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.

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