Kia Picanto (JA): Fuel Delivery System / Fuel Line

Kia Picanto (JA) 2017-2025 Service & Repair Manual / Engine Control / Fuel System / Fuel Delivery System / Fuel Line

Repair procedures

Removal
Low Pressure Fuel Line [High pressure fuel pump ↔ Extension fuel line engine room side]
1.
Release the residual pressure in fuel line.
(Reter to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
2.
Turn the ignition switch OFF, and then remove the battery negative (-) terminal.
3.
Remove the air cleaner.
(Refer to Engine Mechanical System - "Air Cleaner")
4.
Disconnect the fuel feed tube quick-connector (A).

   
Open the clamp cover (A) before disconnecting the quick connector (if the clip is applied).

When removing the quick-connector by using a clip removing tool (A), be careful not to damage the plastic clip (B).
If the clip is damaged, fuel line leakage may occur due to poor connection.

5.
Remove the low pressure fuel line mounting bolt (A) and nut (B).

Low Pressure Fuel Line [Extension fuel line engine room side ↔ Fuel Tank]
1.
Release the residual pressure in fuel line.
(Reter to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
2.
Turn the ignition switch OFF, and then remove the battery negative (-) terminal.
3.
Remove the air cleaner.
(Refer to Engine Mechanical System - "Air Cleaner")
4.
Disconnect the fuel feed tube (A).

5.
Disconnect the vapor hose (A) from the purge control solenoid valve.

6.
Remove the catalytic converter & center muffler assembly.
(Refer to Engine Mechanical System - "Muffler")
7.
Remove the fuel tank.
(Refer to Fuel Delivery System - "Fuel Tank")
8.
Remove the fuel line (A) after loosening the mounting bolts and bracket.

High Pressure Fuel Pipe [High pressure fuel pump ↔ Delivery pipe]
1.
Release the residual pressure in fuel line.
(Reter to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
2.
Turn the ignition switch OFF, and then remove the battery negative (-) terminal.
3.
Remove the air cleaner.
(Refer to Engine Mechanical System - "Air Cleaner")
4.
Disconnect the ignition coil connector (A).
5.
Remove the engine control wiring mounting bolts (B).
6.
Remove the low pressure fuel line mounting bolts (C).

7.
Remove the purge control solenoid valve (PCSV).
(Refer to Engine control System - "Purge Control Solenoid Valve (PCSV)")
8.
Remove the high pressure fuel pipe.
(1)
Remove the flange nut (A) from the high pressure fuel pump by using the special service tool [SST No.: 09314-3Q100 or 09314-27130].

(2)
Remove the flange nut (A) from the delivery pipe by using the special service tool [SST No.: 09314-3Q100 or 09314-27130].

(3)
Remove the high pressure fuel pipe

Installation
1.
Install the fuel line in the reverse order of removal.
2.
Install the high-pressure fuel pipe as follows.
(1)
Completely pre-tighten the both side nuts (A) on high pressure tightening area of high pressure fuel pipe while keeping them vertically.
(2)
Tighten the high pressure fuel pipe function block mounting bolt (B).
Tightening torque :
7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)
(3)
Completely tighten the both side nuts (A) on high pressure tightening area of high pressure fuel pipe.
Tightening torque :
26.5 - 32.4 N·m (2.7 - 3.3 kgf·m, 19.5 - 23.9 lb·ft)

   
•
Do not reuse the high pressure fuel pipe.
•
Be careful not to transform the shape of the high pressure fuel pipe.
•
Torque wrench should not be tilt when you tighten the nut.
•
Follow the order and the tightening torque when you assemble.
•
Inspect fuel leakage after high pressure fuel pipe assembly.
•
Use the special service tool (09314-3Q100) to install the high pressure fuel pipe.

    Repair procedures Removal 1.Remove the fuel pump. (Refer to Fuel Delivery System - "Fuel Pump") 2.Disconnect the fuel pump motor connector (A) and fuel sender connector (B).

    Repair procedures Removal 1. Open the fuel filler door and then remove the filler-neck mounting bolts (A). Filler-neck assembly mounting bolt: 7.

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