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 the Fuel Delivery System - Repair Procedures - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ").
NOTE: When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur.
Delete the code with the GDS after completion of "Release Residual Pressure in Fuel Line" work.
Remove the high pressure fuel pump form
Disconnect the fuel pressure control valve connector (A).

Fig 1: Locating Fuel Pressure Control Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
Open the low pressure fuel tube clip (A).

Fig 2: Locating Low Pressure Fuel Tube Clip
Courtesy of KIA MOTORS AMERICA, INC.
Release the low pressure fuel quick-connector (A) using the clip remover (B).

Fig 3: Removing Low Pressure Fuel Quick-Connector Using Clip Remover
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When removing the low pressure fuel quick-connector, use a clip remover as shown in the image below.

Fig 4: Clip Remover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure fuel pipe.
(Refer to Fuel Delivery System - "FUEL LINE - HIGH PRESSURE FUEL LINE ")
Remove the installation bolts (A), and then remove the high pressure fuel pump from the cylinder head assembly.
NOTE: 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 5: Locating High Pressure Fuel Pump Installation Bolts

Courtesy of KIA MOTORS AMERICA, INC.