Repair Procedures: Removal

High pressure fuel pipe [High Pressure Fuel Pump ↔ Delivery pipe] 

1. Release the residual pressure in fuel line.

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

2. Switch "OFF" the ignition and disconnect the negative (-) battery terminal.
3. Remove the control wiring harness (A).

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4. Remove the high pressure fuel pipe mounting bolts (A).

   High pressure fuel pipe mounting bolt: 

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

   Courtesy of KIA MOTORS AMERICA, INC.

   Courtesy of KIA MOTORS AMERICA, INC.

5. Remove the high pressure fuel pipe flange nut (B).

   High pressure fuel pipe flange nut: 

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

   NOTE: Use the special service tool [SST No.: Ok353-F6100] to install the high pressure fuel pipe and cross over pipe.

   Courtesy of KIA MOTORS AMERICA, INC.

   Courtesy of KIA MOTORS AMERICA, INC.

   Courtesy of KIA MOTORS AMERICA, INC.

6. Remove the high pressure fuel pipe (A).

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High Pressure Fuel Line [Delivery Pipe (Bank 1) Line ↔ Delivery Pipe (Bank 2) Line] 

1. Release the residual pressure in fuel line.

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

2. Switch "OFF" the ignition and disconnect the negative (-) battery terminal.
3. Remove the air cleaner assembly.

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

4. Remove the surge tank.

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

5. Remove the intake manifold

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

6. Remove the cross over high pressure fuel pipe (A).

   Cross over high pressure fuel pipe flange nut: 

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

   Courtesy of KIA MOTORS AMERICA, INC.

Low Pressure Fuel Line [High Pressure Fuel Pump ↔ Extension Fuel Line] 

1. Release the residual pressure in fuel line.

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

2. Switch "OFF" the ignition and disconnect the negative (-) battery terminal.
3. Remove the control wiring harness (A).

   Courtesy of KIA MOTORS AMERICA, INC.

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

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

   Courtesy of KIA MOTORS AMERICA, INC.

   Courtesy of KIA MOTORS AMERICA, INC.