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. So don't do any repair work right after engine stops.

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 ")

CAUTION: When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur.
Delete the code with the KDS/GDS after completion of "Release Residual Pressure in Fuel Line" work.
Remove the air cleaner and the air intake hose.
(Refer to Engine Mechanical System - "INTAKE MANIFOLD ")
Disconnect the fuel pressure regulator valve connector (A).
Disconnect the fuel feed tube quick-connector (B).

Fig 1: Locating Fuel Pressure Regulator Valve Connector And Fuel Feed Tube Quick-Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure fuel pipe.
1. Remove the mounting nut (A) from the high pressure fuel pump with the special service tool [SST No.: 09314-3Q100 or 09314-27130]
2. Remove the mounting nut (B) from the delivery pipe with the special service tool [SST No.: 09314-3Q100 or 09314-27130]
  
  Fig 2: Locating High Pressure Fuel Pipe Mounting Nut
  Courtesy of KIA MOTORS AMERICA, INC.
3. Disconnect the engine coolant temperature sensor connector.
4. Remove the function block (C), and then remove the high pressure fuel pipe.
Fig 3: Locating Function Block
Courtesy of KIA MOTORS AMERICA, INC.
Remove the mounting bolts (D), and then remove the high pressure fuel pump from the cylinder head assembly.
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.

Fig 4: Locating High Pressure Fuel Pump Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.