Repair Procedures: Removal

High pressure fuel pipe (High pressure fuel pipe ↔ Delivery pipe) 

1. Release the residual pressure in fuel line.

   (Refer to the Fuel Delivery System - Repair Procedures - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")

2. Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
3. Remove the camshaft position sensor [bank1/intake]

   (Refer to Engine Control System - CAMSHAFT POSITION SENSOR ")

4. Remove the intake manifold.

   (Refer to Engine Mechanical System - "INTAKE MANIFOLD ")

5. Remove the high pressure fuel pipe function block mounting bolt (A), and then remove the high pressure fuel pipe.

   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 1: High Pressure Fuel Pipe Function Block Mounting Bolt

   Courtesy of KIA MOTORS AMERICA, INC.
6. Remove the installation high pressure fuel pipe flange nut (A, B) from the high pressure fuel pipe with the special service tool [SST No.: 09314-3V100].

   High pressure fuel pipe flange nut: 

   29.4 ~ 35.3 N.m (3.0 ~ 3.6 kgf.m, 21.7 ~ 26.0 lb-ft)

   Fig 2: High Pressure Fuel Pipe Flange Nuts

   Courtesy of KIA MOTORS AMERICA, INC.
7. Remove the high pressure fuel pipe.

Fig 3: High Pressure Fuel Pipe

Courtesy of KIA MOTORS AMERICA, INC.

Low pressure fuel line (Fuel tank ↔ Extension fuel line) 

1. Release the residual pressure in fuel line.

   (Refer to the Fuel Delivery System - Repair Procedures - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")

2. Remove the fuel tank.

   (Refer to Fuel Delivery System - "FUEL TANK ")

3. Disconnect the low pressure fuel feed line quick-connector (A) and vapor line quick-connector (B).
4. Remove the low pressure fuel line (C).

Fig 4: Low Pressure Fuel Feed Line And Vapor Line Quick-Connectors

Courtesy of KIA MOTORS AMERICA, INC.

Low pressure fuel line (Extension fuel line ↔ Extension fuel line side engine room) 

1. Release the residual pressure in fuel line.

   (Refer to the Fuel Delivery System - Repair Procedures - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")

2. Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
3. Remove the air cleaner.

   (Refer to Engine Mechanical System - "AIR CLEANER ")

4. Remove the low pressure fuel line mounting nuts (A).

   Low pressure fuel line mounting nut: 

   3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   Fig 5: Low Pressure Fuel Line Mounting Nuts

   Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the fuel line fixing clip (A).
   Fig 6: Fuel Line Fixing Clip

   Courtesy of KIA MOTORS AMERICA, INC.
6. Lift the vehicle.
7. Remove the front sub frame.

   (Refer to SUB FRAME Suspension System - "Front Sub Frame")

8. Remove the fuel line from the vehicle.

Low pressure fuel line (High fuel pump ↔ Extension fuel line side engine room) 

1. Release the residual pressure in fuel line.

   (Refer to the Fuel Delivery System - Repair Procedures - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")

2. Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
3. Remove the low pressure fuel line mounting nuts (A).

   Low pressure fuel line mounting nut: 

   3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   Fig 7: Low Pressure Fuel Line Mounting Nuts

   Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect the connectors, and then remove the mounting bolts and remove the engine control wiring harness (A).
   Fig 8: Engine Control Wiring Harness Mounting Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the surge tank.

   (Refer to Engine Mechanical System - "SURGE TANK ")

6. Remove the low pressure fuel line mounting nuts (A).

   Low pressure fuel line mounting nut: 

   3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   Fig 9: Low Pressure Fuel Line Mounting Nuts

   Courtesy of KIA MOTORS AMERICA, INC.
7. Remove the low pressure fuel line mounting bolts, and then remove the low pressure fuel line (A).

Fig 10: Low Pressure Fuel Line (1 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

Fig 11: Low Pressure Fuel Line (2 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.