Kia Carnival (2009+). Instruction — part 59

11. Unscrews the timing case mounting bolt (E) after unscrewing the high pressure pump mounting nut (D).

12. Install the SST (No.: OK552 131 003) (F) to the hole (G) of the sprocket.

13. Push the high pressure pump from the timing case by using the tightening bolts (H).

INSTALLATION

• Common Rail Fuel Injection System is subject to extremely high pressure (Approximately 1,600 bar)
• Never perform any work on injection system with engine running or within 30 seconds after the engine stops.
• Always pay attention to safety precaution.
• Ensure the absolute cleanliness.
• It is not recommended to remove the injectors without any notice.
• Take care that the foreign material does not enter to the components when you remove or install the Fuel

system.

• Clean the connction parts of injector and replace the O-ring when you remove or install the injector.
• Insert the O-ring in the Cylinder head after pasting Diesel oil to the O-ring gasket.
• Avoid damaging the injector when you insert the injector into the cylinder.
• High pressure fuel pipe should not be reused.
• Mount the flare nut and the component vertically when you install the high pressure fuel pipe.

1. Install the High pressure pump according to the reverse order to REMOVAL procedure.

1. When you install the high pressure pump bracket mounting bolt, Install the bracket as following order.

Cylinder block side -> High pressure pump side

2. Remove the sprocket fixing bolt (SST: OK552 131 003) after the high pressure pump set to the timing case

completely.

Install the flange nut (High pressure pump & Common rail side) with SST as following specification.

Classification

SPEC

SST No.

Flange nut (Common rail)

19mm (0.74 in.)

09314-27130

Flange nut (High pressure pump)

19mm (0.74 in.)

09314-27130

Tightening torque:
Flange nut (Common rail): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
Flange nut (High pressure pump): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
High pressure pipe clamp mounting bolt: 2.9 N.m (0.3 kgf"m, 2.2 lbf.ft)
Bracket mounting bolt (Cylinder block): 34.3 ~ 40.2 N.m (3.5 ~ 4.1 kgf"m, 25.3 ~ 29.7 lbf.ft)
Bracket mounting bolt (High pressure pump): 21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf"m, 15.9 ~ 18.8 lbf.ft)
High pressure pump mounting bolt (Timing case): 21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf"m, 15.9 ~ 18.8 lbf.ft)

Fuel System

Fuel Delivery System - Fuel Sender

Fuel System

2009 > D 2.9 VGT >

REMOVAL

1. Remove the second seat (Refer to "BD" group in this WORKSHOP MANUAL).

2. Remove the Service cover (A).

3. Disconnect the Fuel sender connector (A), the Fuel supply hose Quick - connector (B) and the Fuel return hose

Quick - connector (C).

4. Unscrew the fuel sender mounting bolt (D) and than remove the fuel sender.

INSTALLATION

1. Install the Fuel Sender according to the reverse order to REMOVAL procedure.

Tightening Torques
Fuel tank installation bolts: 2 ~ 2.9 N!m (0.2 ~ 0.3 kg!m, 1.4 ~ 2.2 lb!ft)