Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.

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.

Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")
Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
Remove the intake manifold.
(Refer to Engine Mechanical System - "INTAKE MANIFOLD ")
Remove the drive belt.
(Refer to Engine Mechanical System - "DRIVE BELT ")
Remove the injector foam (A).

Fig 1: Locating Injector Foam
Courtesy of KIA MOTORS AMERICA, INC.
Make a gap (B) between the alternator (A) and the engine assembly by pulling the alternator in the direction of arrow.

Fig 2: Making Gap Between Alternator And Engine Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure fuel pipe (A) after loosening the high pressure fuel pipe flange nuts (B) and function block mounting bolt (C).
High pressure fuel pipe flange nut:

26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb.ft)

High pressure fuel pipe function block mounting bolt:

9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)

Fig 3: Removing High Pressure Fuel Pipe
Courtesy of KIA MOTORS AMERICA, INC.
Remove the delivery pipe & injector assembly (B) after loosening the mounting bolt (A).
Delivery pipe & injector assembly mounting bolt:

18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

Fig 4: Removing Delivery Pipe & Injector Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the injector & rail pressure sensor connector (A).

Fig 5: Disconnecting Injector & Rail Pressure Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the injector (A) from the delivery pipe.

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