Kia Sedona: High Pressure Fuel Pump Repair procedures

Third generation YP (2014-2025) / Kia Sedona YP Service Manual / Engine Control / Fuel System / Fuel Delivery System / High Pressure Fuel Pump Repair procedures

Removal

When removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, injury may be caused by leakage of high pressure fuel. For this reason, do not attempt any repairing immediately after engine stops.

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 high pressure fuel fump foam (A).

4.	Disconnect the fuel pressure control valve connector (A) and fuel feed tube quick-connector (B).

5.	Remove the intake manifold. (Refer to Engine Mechanical System - "Intake Manifold")

6.	Remove the high pressure fuel pipe. (Refer to Fuel Delivery System - "Fuel Line")

Remove the mounting bolts (A), and then remove the high pressure fuel pump (B) from the cylinder head assembly

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). When one of the two bolts is fully unscrewed while the other bolt still intact, the housing surface of the cylinder head may be broken due to tension of the pump spring.

Installation

•	Be sure that the low pressure fuel hose quick-connector (A) is completely connected to the high pressure fuel pump by the locking sound.

•	Double-check the complete connection of the low pressure fuel hose to the high pressure fuel pump by pulling it after connecting.

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

•	Because fuel leak may cause fire, thoroughly 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 be broken because of tension of the pump spring.

•	Do not reuse the used bolt.

•	Do not reuse the used high pressure fuel pipe.

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

•	Install the component with the specified torques.

•

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.

Bolts or nuts not tightened in a straight line with the matching bolt holes or fittings may cause fuel leakage 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.: 09314-3V100] to install the high pressure fuel pipe.

Fuel Line Repair procedures

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Kia Sedona: High Pressure Fuel Pump Repair procedures

Fuel Line Repair procedures

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