Kia Sorento: High Pressure Fuel Pump Removal and Installation

Removal

1.	Release the residual pressure in fuel line. (Refer to the Fuel Delivery System - "Release Residual Pressure in Fuel Line")

2.	Disconnect the battery negative ( - ) terminal.

3.	Remove the air cleaner. (Refer to Engine Mechanical System - "Air Cleaner")

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

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

Engine Control / Fuel System — Fuel Delivery System / High Pressure Fuel Pump / Removal and Installation / Removal illustration

•	Pull the fuel injection tube quick-connector (A) cover (B) in the arrow direction.

•	Remove the quick-connector (B) after pressing the quick-connector button (A) and pulling fuel injection tube in the arrow direction.

Remove the high pressure fuel pump after removing the mounting bolts (A).

Tightening torque :

12.7 - 14.7 N·m (1.3 - 1.5 kgf·m, 9.4 - 10.8 lb·ft)

Engine Control / Fuel System — Fuel Delivery System / High Pressure Fuel Pump / Removal and Installation / Removal illustration

Installation

After checking the pump drive cam position, turn the damper pulley to BDC position.

If the cam is installed in a position other than the BDC, the following problems may occur.

•	O-ring damage due to incomplete tightening.

•	High pressure pump piston tightening bolt thread damage.

Apply engine oil to the O-ring (A), roller tappet (B), guide pin (C) and mounting groove of the high pressure fuel pump.

Engine Control / Fuel System — Fuel Delivery System / High Pressure Fuel Pump / Removal and Installation / Installation illustration

Replace the O-ring with new one. (Do not reuse)

After mounting the high pressure fuel pump and the roller tappet, tighten the bolts (A) by hand.

Engine Control / Fuel System — Fuel Delivery System / High Pressure Fuel Pump / Removal and Installation / Installation illustration

•	Install the mounting bolts (A) alternately by 0.5 turns. If only one of the two bolts is completely fastened, the housing surface of the cylinder head may be damaged due to the high pressure fuel pump spring tension.

•	Do not reuse the bolt.

Tighten the high pressure fuel pump bolts with specified torque.

Tightening torque :

12.7 - 14.7 N·m (1.3 - 1.5 kgf·m, 9.4 - 10.8 lb·ft)

5.	Connect the fuel pressure control valve connector (A) and the fuel feed quick-connector (B).

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

7.	Install the air cleaner. (Refer to Engine Mechanical System - "Air Cleaner")

8.	Connect the battery negative ( - ) terminal.

9.	Check for leakage the fuel after installation.

Specification Item Specification Coil resistance (Ω) 1.15 - 1.50 [20°C (68°F)]...

Injector Specifications Specification Item Specification Coil resistance (Ω) MPI ...

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