Repair Procedures: Removal

CAUTION: 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.

Release the residual pressure in fuel line.
(Refer to the Fuel Delivery System - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")
Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
Disconnect the injector & rail pressure sensor extension connectors (A).

Fig 1: Disconnecting Injector & Rail Pressure Sensor Extension Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intake manifold.
(Refer to Engine Mechanical System - "INTAKE MANIFOLD ")
Remove the high pressure fuel pipe function block mounting bolt (A).
High pressure fuel pipe function block mounting bolt: 7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb.ft)

Fig 2: Removing High Pressure Fuel Pipe Function Block Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure fuel pipe after loosening the high pressure fuel pipe flange nuts (A).
High pressure fuel pipe flange nut (A): 26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb.ft)

Fig 3: Loosening High Pressure Fuel Pipe Flange Nut (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 4: Loosening High Pressure Fuel Pipe Flange Nut (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the injector foam (A).

Fig 5: Removing Injector Foam
Courtesy of KIA MOTORS AMERICA, INC.
Remove the mounting bolt (A), and then remove the delivery pipe & injector assembly from the engine.
Delivery pipe & injector assembly mounting bolt (C): 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

Fig 6: Removing Delivery Pipe & Injector Assembly From Engine
Courtesy of KIA MOTORS AMERICA, INC.