Fuel System - GDI Fuel System Service Info/Specs
NUMBER 083GROUP Engine
DATE August 2011
MODEL All Vehicles equipped with GDI
SUBJECT: SPECIAL SERVICE INFORMATION AND SPECIFICATIONS FOR GDI HIGH PRESSURE FUEL SYSTEM
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, serviceing 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.
^ 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" shown below before removing any high pressure fuel system components.
Service Procedure
Fuel Pressure Specification Comparison
CAUTION
The GDI high pressure fuel system operates at considerably higher fuel pressures then the conventional MPI fuel system.
High Pressure Fuel System Tightening Torque
CAUTION
When installing the high pressure fuel pump, fuel pipe, or the delivery pipe, be sure to follow the tightening torque specifications listed in the table below a torque wrench. Failure to do so may cause damage to the fuel line connections and may result in fuel leaks.
^ Fully tighten the fasteners by hand without using a tool. During this time, check for proper positioning of the fittings and components.
^ Afterwards, completely tighten to the specified torque using a torque wrench.
^ If the fasteners are not tightened in a straight line with the mating bolt holes or fittings, a fuel leak may result due to misalignment, broken fasteners or damaged threads.
High Pressure Fuel System Tightening Torque
SST For Tightening High Pressure Fuel Pipe Flare Nuts
A: Fuel Pipe Flare Nuts
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. Release the residual pressure in the high pressure fuel line by refurring to the "Residual Fuel Pressure Release Procedure" shown below before removing any high pressure fuel system components.
Residual Fuel Pressure Release Procedure:
Wear safety glasses and fuel resistant gloves.
^ 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 20 seconds to lower the pressure in both the high or low pressure lines. The engine may shut off within the 20 second period. If not, turn the engine off.
^ Proceed with the service or repair. Use rags to cover opening and catch spills when opening up either fuel lines.
^ Reinstall/re-connect all components in reverse order of removal. Start the engine and confirm proper operation, and make sure there are no fuel leaks.
^ After completing, clear DTC's using GDS scan tool (the procedure described above will cause DTC to set).
High Pressure Fuel Pump Installation
Before installing the high pressure fuel pump, be sure to place the fuel pump drive cam to the flat part of the lobe (as shown below) by rotating the crankshaft. If the drive cam for 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, damaged threads, damaged O-ring, etc.
B: Fuel Pump, C: Adapter Bracket (Cylinder Head Cover), D: Roller Tappet, E: Fuel Pump Drive Cam.
^ 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 installing the fuel pump mounting bolts, hand-thread the fasteners first, then gradually tighten 1/2 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 grove in the fuel pump mounting hole.
High Pressure Fuel Pump Installation
^ Do not reuse the fuel pipe. Once the fuel pipe is removed, it must be replaced 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 in this TSB to properly install the high pressure fuel pipe.
Delivery Pipe and Injector Installation
^ Do not reuse the delivery pipe mounting bolts. Once the delivery pipe is removed, the bolts must be replaced with new ones.
^ Do not reuse the injector retaining clip0, O-ring, backup ring, washer seal or combustion seal ring. Once an injector is removed, the five components must be replaced with new ones.
When installing the combustion chamber seal ring onto the injector, use the SST 09353-2B000 (as shown below) and refer to the instructions below.
Injector Combustion Seal Installation Procedure
1. Place the Combustion Seal on the cone and pull downward on the seal as indicated in the photo.
*NOTICE
Your fingers will work better for installing the Combustion Seal over the cone.
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 grove.
4. Because the seal will stretch as it goes over the end of the injector, it will be a bit oversized after installation.
By letting the injector and seal set foe a few minutes, the seal may reduce in size.
Inspect the seal for damage before continuing.
5. 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 on the combustion seal ring.
6. Place 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.
8. If the injector comes with a protective steel washer held in place by a spring clip; both will have to be removed before installation.
9. Install the Washer Seal onto injector with the rubber side (stepped) toward the injector.
10. The stepped rubber side of the seal goes towards the injector.
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 on the combustion seal ring.
^ Avoid dropping the fuel pipe (including injectors) or bumping it into any hard objects since damage to internal components may occur. If necessary, visually inspect and confirm proper operation with performance test 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 above) in several cycles up to the specified torque. The delivery pipe should move less then 1/8 inch (approx. 3mm), whenever each bolt is tightened.
Refer to the EPC for the latest part number information concerning mandatory replacement/"no reuse" parts.