Kia Stinger: Engine Control / Fuel System / Fuel Delivery System

Whenever the high pressure fuel pump, fuel pipe, delivery pipe, or injector is removed immediately after shutting off the engine, an injury may be caused by the release of highly pressurized fuel. Release the residual pressure in the high pressure fuel line by referring to the "Residual fuel pressure release procedure" below before removing any high pressure fuel system components.

Release the residual pressure in fuel line.

(Refer to the Fuel Delivery System - Inspection - "Release Residual Pressure in Fuel Line".)

When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the KDS after completing to “Release Residual Pressure in Fuel Line”.

Install the Special Service Tool (SST).

(1)	Disconnect the fuel feed tube from the delivery pipe. There may be some residual pressure even after completing to “Release Residual Pressure in Fuel Line”, so cover the hose connection with a shop towel to prevent residual fuel from spilling out before disconnecting any fuel connection.

Check for fuel leakage from connections on the low fuel feed tube, the low pressure inlet of high pressure fuel pump, and the SST components with ignition "ON".

Measure the fuel pressure.

(1)

Start the engine and measure the fuel pressure at idle. Fuel Pressure: Over 290 kPa (Over 2.9 bar, Over 2.95 kgf/cm², Over 42.06 psi) If the measured fuel pressure is out of specification, repair or replace the related part. (Refer to the table below.) Fuel Pressure Cause Related Part Too Low Fuel filter clogged Fuel Filter Fuel leakage Fuel Pressure Regulator Too High Fuel pressure regulator stuck Fuel Pressure Regulator

(2)

Stop the engine, and then check for the change in the fuel pressure gauge reading. Standard Value: The gauge reading should hold for about 5 minutes after the engine stops If the gauge reading could not be held, repair or replace the related part. (Refer to the table below.) Fuel Pressure (After Engine Stops) Cause Related Part Fuel Pressure Drops Slowly Leakage on injector Injector Fuel Pressure Drops Immediately Check valve of fuel pump stuck open Fuel Pump

Release the residual pressure in fuel line.

(Refer to the Fuel Delivery System - Repair Procedures - "Release Residual Pressure in Fuel Line").

When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the KDS after completing to “Release Residual Pressure in Fuel Line”.

Finish test.

Whenever the high pressure fuel fuse, fuel pipe, delivery pipe, or injector is removed immediately after shutting off the engine, an injury may be caused by the release of highly pressurized fuel. Release the residual pressure in the high pressure fuel line by referring to the "Residual fuel pressure release procedure" below before removing any high pressure fuel system components.

Wear safety glasses and fuel resistant gloves.

Switch "OFF" the ignition and disconnect the negative (-) battery terminal.

Remove the fuel pump relay (A).

Reconnect the negative (-) battery terminal.

Run the engine for about 1 minute to lower the pressure in the low pressure line.

Turn the engine off.

Disconnect the low pressure fuel line quick connector at the High Pressure Pump. Use rags to cover opening and catch spills while removing the fuel line.

Start the engine and let it idle until the engine stops. At this point the pressure should be under 30 psi.

Proceed with the service or repair. Use rags to cover opening and catch spills when opening up the high pressure system.

Reinstall / re-connect all components in reverse order of removal. Start engine and confirm proper operation, and make sure there are no fuel leaks.

After completing, clear DTC(s) using KDS scan tool. (The procedure described above will cause DTC to set.)