TSBENG083_R1

GROUP
ENG
NUMBER
083 (Rev 1, 01/18/2019)
MODEL
All Models
equipped with GDI
Fuel System
DATE
August 2011
TECHNICAL SERVICE BULLETIN
SUBJECT:
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM
 NOTICE
This bulletin has been revised to include additional information. New/revised
sections of this bulletin are indicated by a black bar in the margin area.
This bulletin provides information relating to all Kia vehicles equipped with Gasoline Direct
Injection (GDI) engines. In these engines highly pressurized gasoline is injected via a common
fuel rail and injectors that deliver fuel directly into the combustion chamber of each cylinder. In
comparison, in a conventional Multi-Point Fuel Injection (MPI) engine, the gasoline is injected
into the intake port of each cylinder at a relatively low pressure. Due to high fuel pressure in
a GDI system, servicing the GDI system requires special attention and handling
procedures.
This bulletin provides special service information and specifications for the GDI fuel system
components. The following aspects of the GDI fuel system will be outlined:







Fuel Pressure Specification Guideline
High Pressure Fuel System Tightening Torque
SST For Tightening High Pressure Fuel Pipe Flare Nuts
High Pressure Fuel System Residual Pressure Warning
High Pressure Fuel Pump Installation
High Pressure Fuel Pipe Installation
Delivery Pipe and Injector Installation
WARNING
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. Therefore, release the residual pressure in the
high pressure fuel line by referring to the “Residual Fuel Pressure Release
Procedure” on page 2 before removing any high pressure fuel system components.
File Under: 
Circulate To:
X General Manager

X Service Advisors

X Technicians

X Service Manager

X Parts Manager

X Body Shop Manager 
X Fleet Repair

Page 2 of 10
SUBJECT:
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM
WARNING
If the following parts have been uninstalled, they MUST be replaced as they are onetime-use components. DO NOT REUSE! Failure to replace these components may
result in fuel leaks.
 High Pressure Fuel Pump Bolts
 High Pressure Fuel Line
 Fuel Rail (Delivery Pipe) Bolts
Service Procedure:
Fuel Pressure Specification Comparison (MPI vs GDI)
MPI (Low Pressure)
GDI (High Pressure)
2
43-64 psi (3.0~4.5 kgf/cm )
(Regulated by Fuel Pressure Regulator)
2
569-2133 psi (40~150 kgf/cm )
(High Pressure Fuel Line)
 NOTICE
The GDI High Pressure Fuel system operates at considerably higher fuel pressure
than the conventional MPI Fuel System.
Special Cautions When Servicing High Pressure Fuel System
WARNING
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. Therefore, 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.
Residual Fuel Pressure Release Procedure
Wear safety glasses and fuel resistant gloves.
1.
2.
3.
4.
Turn the ignition off and disconnect the battery negative (-) cable.
Remove the fuel pump relay and the electrical connector to the High Pressure Fuel Pump.
Reconnect the battery negative (-) cable.
Run the engine for about twenty (20) seconds to lower the pressure in both the high or low
pressure lines. The engine may shut off itself within twenty (20) seconds. If it does not shut
off, turn the engine off.
5. Proceed with the service or repair. Use rags to cover the opening and catch spills when
opening up either fuel line. Follow the installation procedure on page 3.
6. Reinstall / reconnect all components in the reverse order of removal. Start engine to confirm
proper operation and make sure there is no fuel leak.
7. After completing, clear DTC(s) using the KDS as this procedure may set a DTC(s).
TSB: ENG083 (Rev 1) Multiple Models August 2011
Page 3 of 10
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM
SUBJECT:
High Pressure Fuel System Tightening Torque
CAUTION
When installing the High Pressure Fuel Pump, Fuel Pipe, or Fuel Rail (Delivery Pipe),
be sure to follow the tightening torque specifications listed in the applicable Shop
Manual on KGIS using a torque wrench. Failure to do so may cause damage to the
fuel line connections and may result in fuel leaks.
1
1. High Pressure
Fuel Pump
3
2. High Pressure
Fuel Pipe
2
3. Clamp
4
Tightening Torques:
Refer to the applicable Shop
manual on KGIS:
Engine Control / Fuel System →
Fuel Delivery System →
“Component” → Repair procedures
4. Delivery Pipe
SST for Tightening High Pressure Fuel Pipe Flare Nuts
Tool Name &
Number
Figure
Tool Usage
Flare Nuts (A)
Torque Wrench
Socket
(09314-3Q100)
Used for both Flare Nuts
of Fuel Pipe
High Pressure Fuel System Installation Procedure
Perform the steps below in the following order to install the high pressure fuel system. Refer to
pages 4-5 for more details.
Click here to see a video tutorial.
1.
2.
3.
4.
5.
6.
Install the Roller Tappet.
Install the High Pressure Fuel Pump and NEW Bolts and torque to specifications.
Position Fuel Pipe properly and then hand-tighten the Flare Nuts.
Transfer the retaining bracket from the old Fuel Pipe.
Install the retaining bracket bolt and torque to specifications.
Using the Torque Wrench Socket (09314-3Q100), torque both Flare Nuts.
TSB: ENG083 (Rev 1) Multiple Models August 2011
Page 4 of 10
SUBJECT:
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM
Before installing the high pressure fuel pump, be sure to place the roller tappet to the lowest
position, and then position the fuel pump drive cam to the flat part of the lobe (as shown below)
by rotating the crankshaft. If the roller tappet of the fuel pump is not placed in the lowest
position during installation, the fuel pump may be positioned improperly, which may result in
fuel pump piston damage, broken bolt threads, damaged O-ring, etc.
B
C
D
E
B) Fuel Pump, C) Adapter Bracket (Cylinder Head Cover), D) Roller Tappet, E) Fuel Pump Drive

During a repair requiring fuel pump removal, cover the exposed fuel pump mounting hole in
the adapter bracket to prevent any foreign substance or debris contamination.

Do not reuse the fuel pump mounting bolts. Once a fuel pump is removed, the
removed bolts must be replaced with new ones.

When fastening the fuel pump mounting bolts, hand-thread the fasteners first, then
gradually tighten ½ turn at a time to the specified torque while alternating between the two
bolts in several cycles using a torque wrench. Failure to follow this procedure will cause
misalignment to the assembly due to internal spring tension of the fuel pump and can result
in damage to the adapter bracket.

Do not drop the fuel pump. External impacts may damage the internal components of the
fuel pump. If this has occurred, confirm proper operation through performance tests prior to
reuse.

Before installing the fuel pump into the adapter bracket, be sure to apply clean engine oil
evenly over the entire surface of the O-ring, roller tappet, and fuel pump mounting hole.
When installing the fuel pump, align the protrusion on the roller tappet to the groove in the
fuel pump mounting hole.
F) Align protrusion to groove.
G) Roller tappet (apply oil)
H) Fuel Pump mounting hole (apply
oil)
I) Fuel Pump
J) O-ring (apply oil)
TSB: ENG083 (Rev 1) Multiple Models August 2011
Page 5 of 10
SUBJECT:
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM

Do not reuse the fuel pipe. Once the fuel pipe is removed, it must replace with a new one.

There are protective caps on both ends of the replacement fuel pipe to prevent foreign
substances from entering into the fuel pipe. Remove the caps prior to installing the fuel pipe
to the fuel pump and the delivery pipe.

Refer to the “High Pressure Fuel System Tightening Torque” section on page 3 of this TSB
for details regarding proper installation of the High Pressure Fuel Pipe.
K)
L)
M)
N)
Fuel Pipe (Delivery Pipe)
Fuel Pump
Fuel Pipe
Pipe Retaining Bracket
WARNING
If the following parts have been uninstalled, they MUST be replaced as they are onetime-use components. DO NOT REUSE! Failure to replace these components may
result in fuel leaks.
 High Pressure Fuel Pump Bolts
 High Pressure Fuel Line
 Fuel Rail (Delivery Pipe) Bolts
WARNING
Do not release any vehicle after GDI component related repairs without verifying that
the system is leak free; once all components are reinstalled/reconnected, start the
engine to confirm proper operation and make sure there is/are no fuel leak(s),
especially at the high pressure lines/connections.
Fuel Pipe (Delivery Pipe) & Injector Installation

Do not reuse the fuel pipe mounting bolts. Once the fuel pipe is removed, the bolts must be
replaced with new ones.

Do not reuse the injector retaining clip, O-ring, backup ring, washer seal, and combustion
seal. Once an injector is removed, the five components must be replaced with new ones.
TSB: ENG083 (Rev 1) Multiple Models August 2011
Page 6 of 10
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM
SUBJECT:
O) Injector Retaining Clip
P) Injector Combustion Seal
Ring
Q) Injector O-RingInjector
R) Backup Ring
S) Injector Washer Seal
Note: Items P, Q, and R are
supplied in a single kit.
When installing the combustion seal ring into the injector, use the SST 09353-2B000 (as shown
below) and refer to the “Fuel System – Engine Control System – Injector” section in the
appropriate Service Manual.
Tool Name
Tool Number
Components
1
2
Injector Combustion
Seal Ring Installer
① Sizing Tool
② Guide
③ Pushing Tool
09353-2B000
3
 NOTICE
The combustion seal is a one-time use part and MUST be replaced if the injector is
uninstalled.
1.
Place the Combustion Seal on the cone
and pull downward on the seal as
indicated in the photo.
 NOTICE
Using bare fingers without
gloves will work better for
installing the Combustion Seal
over the cone.
TSB: ENG083 (Rev 1) Multiple Models August 2011
Page 7 of 10
SUBJECT:
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM
2.
Pull the seal downward until it is near the
bottom of the cone as shown in the
photo.
3.
Place the cone (with seal) on the end of
the injector.
Place the sizing tool (09353-2B000) over
the cone. Make sure the tool flange is
toward the seal as shown.
Press down on the tool to work the seal
over the injector and into the groove.
4.
Because the seal will stretch as it goes
over the end of the injector, it will be a bit
oversize after installation.
By letting the injector and seal set for a
few minutes, the seal may reduce in size.
Inspect the seal for damage before
continuing.
TSB: ENG083 (Rev 1) Multiple Models August 2011
Page 8 of 10
SUBJECT:
5.
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM
Place the resizing tool (flange up) over
the seal. Twist the tool slightly while
pushing down over the seal. This should
reduce the size of the seal.
Be careful not to apply engine oil on the
combustion seal ring.
6.
Place the injector into the head as
shown.
7.
Twist slightly while pressing the injector
into position in the head.
This should complete the resizing of the
seal.
Remove the injector and inspect the seal
before completing the injector installation
process.
TSB: ENG083 (Rev 1) Multiple Models August 2011
Page 9 of 10
SUBJECT:
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM
8.
If the injector comes with a protective
steel washer held in place by a spring
clip, both steel washer and spring clip will
have to be removed before installation.
9.
Install the washer seal onto the injector
with the rubber side (stepped) toward the
injector.
10. The stepped rubber side of the seal goes
towards the injector.
TSB: ENG083 (Rev 1) Multiple Models August 2011
Page 10 of 10
SUBJECT:
SPECIAL SERVICE INFORMATION & SPECIFICATIONS
FOR GDI HIGH PRESSURE FUEL SYSTEM
11. The flat washer side of the seal goes
towards the head.

Before installing the injectors into the delivery pipe, be sure to apply clean engine oil
evenly over the entire surface of the injector O-ring. Be careful not to apply engine oil
over the combustion seal ring.

Avoid dropping the fuel pipe (including injectors) or bumping it into any hard objects
since damage to the internal components may occur. If necessary, visually inspect
and confirm proper operation with performance tests prior to reuse.

Before installing the injector into the cylinder head, clean the injector hole and avoid
contaminants from entering inside the injector hole. When installing the injector, avoid
bumping the injector tip into any of the surrounding components since the tip may
become damaged from the impact.

When fastening the three fuel delivery
pipe mounting bolts, fully hand-tighten
first, and then tighten in the proper
sequence (see photo on the right) in
several cycles up to the specified torque.
The delivery pipe should move less than
1/8 inch (3mm), whenever each bolt is
tightened.
Refer to EPC for the latest part number information concering mandatory replacement /
“no reuse” parts.
WARNING
Do not release any vehicle after GDI component related repairs without verifying that
the system is leak free; once all components are reinstalled/reconnected, start the
engine to confirm proper operation and make sure there is/are no fuel leak(s),
especially at the high pressure lines/connections.
TSB: ENG083 (Rev 1) Multiple Models August 2011