Kia Picanto: Fuel Delivery System / High Pressure Fuel Pump

Kia Picanto JA 2017-2023 Service & Repair Manual / Engine Control / Fuel System / Fuel Delivery System / High Pressure Fuel Pump

High Pressure Fuel Line
20  - 200
2 - 20
20.4 - 203.9
290.1 - 2900.8

Repair procedures
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
Turn the ignition switch OFF, and then remove the battery negative (-) terminal.
Remove the air cleaner.
(Refer to Engine Mechanical System - "Air Cleaner")
Disconnect the fuel pressure control valve (FPCV) connector(A) and ignition coil connector(B).
Remove the engine control wiring mounting bolts(C).

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.

Remove the purge control solenoid valve (PCSV).
(Refer to Engine Control System - "Purge Control Solenoid Valve (PCSV)")
Remove the high pressure fuel pump.

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

Unfasten the mounting bolts (A) and then remove high pressure fuel pump.

Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the crankshaft. Otherwise the installation bolts may break due to the tension on the pump spring.
Keep away from foreign materials when assembling.
Do not reuse the bolt.
Do not reuse the high pressure fuel pipe.
When tightening the installation bolts of the high pressure fuel pump, pretighten the bolts by hand, and then fully tighten in turns in small steps (0.5 turns).
Install the component to the specified torques.
First, pretighten the fasteners by hand until they are not fastened anymore in order to have them inserted in place, and then using a torque wrench, fully tighten them to the specified torque.
If the bolts or nuts are not tightened in a straight line with the mating bolt holes or fittings, fuel leakage may occur due to broken threads.
Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove on the location where the protrusion (C) is installed.

Install in the reverse order of removal.
Use the special service tool [SST No.: 09314-3Q100 or 09314-27130] to install the high pressure fuel pipe.
Delivery Pipe
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