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

Kia Stinger CK 2018-2020 Service Manual / Engine Control / Fuel System / Fuel Delivery System

Components and components location
Components Location
Fuel Tank & Filler-Neck Assembly

1. Fuel Tank
2. Low Pressure Fuel Pump
3. Sub Fuel Sender
4. Fuel Filler Hose
5. Leveling Hose
6. Ventilation Hose
7. Filler-Neck Assembly
8. Fuel Pump Plate Cover

Low Pressure Fuel Pump

1. Fuel Feed Port
2. Fuel Pressure Sensor (FPS)
3. Fuel Filter
4. Fuel Sender
5. Fuel Pressure Regulator
6. Head Assembly
7. Reservoir-Cup
8. Pre-filter

High Pressure Fuel Line

1. High Pressure Pump
2. High Pressure Pipe
3. Delivery Pipe
4. Injector
5. Rail Pressure Sensor (RPS)

  

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.

Fuel pressure test (low pressure system)
Fuel Pressure Test (Low pressure system)
1.

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”.

2.

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.

(2)

Install the special service tool for measuring the fuel pressure in between the fuel feed tube and the fuel delivery pipe. (Refer to the figure below.)

For 09353-02100

For 0K353-D4100

3.

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".

4.

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

(3)

Switch "OFF" the ignition.

5.

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”.

6.

Finish test.

(1)

Remove the Special Service Tool (SST) from the low pressure fuel feed tube and the low pressure inlet of high pressure fuel pump.

(2)

Connect the low pressure fuel feed tube and the low pressure inlet of high pressure fuel pump.

Release residual pressure in fuel line
Release Residual Pressure in Fuel Line
  

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.

1.

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

2.

Remove the fuel pump relay (A).

3.

Reconnect the negative (-) battery terminal.

4.

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

5.

Turn the engine off.

6.

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.

7.

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

8.

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

9.

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

10.

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

Hood switch
Description and operation Description Hood switch is one of the factors influencing the activation of the ISG function. When the hood is open, the engine will not start or stop by the ...

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

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