Kia Niro: Fuel Delivery System / High Pressure Fuel Pump Repair procedures

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

When removing the quick-connnector with the clip removing tool (A), be careful not to damage the plastic clip (B).

Damaged clip can result in fuel line leakage due to bad connection.

High pressure fuel pump mounting bolt:

12.8 - 14.7 N·m (1.3 - 1.5 kgf·m, 9.4 - 10.9 lb·ft)

Unscrew in turns the two bolts in small steps (0.5 turns). If one of the two bolts is fully unscrewed with the other still intact, the housing surface of the cylinder head may get broken due to the tension of the pump spring.

To ensure that the low pressure fuel hose quick-connector (A) is completely engaged to the high pressure fuel pump, push it in until it clicks.

To double check that the low pressure fuel hose is completely engaged to the high pressure fuel pump, pull it after connecting.

Install the clamp cover (A) to tighten the quick-connector completely.

Be sure to install the high pressure fuel pipe (B) to the specified torque.

Securely inspect leakage of all fuel line connection parts at engine start condition.

Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the crankshaft. Otherwise the installation bolts may get broken due to tension of the pump spring.

Do not reuse bolts.

Do not reuse high pressure fuel pipes.

When tightening the installation bolts of the high pressure fuel pump, tighten in turns the bolts in small steps (0.5 turns) after pre-tightening them by hand.

Install the component to the specified torque.

First hand-tighten the fasteners fully until they are not fastened any more in order to have them inserted in place and then completely tighten to the specified torque using a torque wrench.

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.

Use the special service tool [SST No.: 09314-3Q100 or 09314-27130] to install the high pressure fuel pipe.