Kia Sportage: Fuel Delivery System / Fuel Line Repair procedures

Kia Sportage QL (2015-2025) Service Manual / Engine Control / Fuel System / Fuel Delivery System / Fuel Line Repair procedures

Removal

Be careful not to damage the fuel line during repair.

In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don’t do any repair work right after engine stops.

Low Pressure Fuel Line [High Pressure Fuel Pump ↔ Fuel Tank]

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

2.	Turn the ignition switch OFF, and then remove battery (-) terminal.

3.	Remove the battery. (Refer to Engine Electrical System - "Battery")

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

Disconnect the fuel feed tube quick-connector (A).

Open the clamp cover (B) before disconnect 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).

If the clip is damaged, fuel line leak can be occurred due to a bad connection.

6.	Disconnect the vapor hose (A) which is connected from the PCSV.

7.	Remove the fuel tank. (Fuel Delivery System - "Fuel Tank")

8.	Remove the bracket (A) after loosening the mounting bolts.

9.	Remove the fuel line (A) after loosening the mounting bolts and bracket.

High Pressure Fuel Line

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

2.	Turn the ignition switch OFF and then remove the battery negative (-) terminal.

3.	Disconnect the ignition coil #4 connector.

Remove the high pressure pipe flange nut (A) in order of with the special service tool (B) [SST No.: 09314-3Q100]

High pressure fuel pipe flange nut:

26.5 - 32.4 N·m (2.7 - 3.3 kgf·m, 19.5 - 23.9 lb·ft)

Remove the high pressure fuel pipe function bolck mounting bolt (A).

High pressure fuel pipe function block mounting bolt:

7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Installation

1.	Install in the reverse order of removal.

Fuel Pressure Sensor (FPS) Repair procedures

Inspection 1. Connect the KDS/GDS on the Data Link Connector (DLC). 2. Check the output voltage of fuel pressure sensor (FPS). ...

Filler-Neck Assembly Repair procedures

Removal 1. Open the fuel filler door. 2. Turn ignition switch OFF and disconnect the battery negative (-) terminal. ...

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