Kia Carnival (2009+). Manual — part 58

• 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 Common rail according to the reverse order to REMOVAL procedure.

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

Flange nut (Injector)

17mm (0.67 in.)

09314-27120

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 (Common rail): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
Flange nut (Injector): 35.8 ~ 42.7 N.m (3.65 ~ 4.35 kgf"m, 26.4 ~ 31.5 lbf.ft)
High pressure pipe(Common rail !High pressure pump) clamp mounting bolt: 2.9 N.m (0.3 kgf"m, 2.2
lbf.ft)
Common rail mounting bolt : 18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf"m, 13.7 ~ 16.6 lbf.ft)

Fuel System

Fuel Delivery System - High Pressure Pump

Fuel System

2009 > D 2.9 VGT >

REMOVAL

• 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. Remove the cooling fan (Refer to "EM" group in this WORKSHOP MANUAL)

2. Remove the high pressure pipe (High pressure pump ! Common rail).

(1) Unscrews the flange nut (A) at the common rail.

(2) Unscrews the flange nut (A) at the side of the high pressure pump.

(3) Remove the high pressure pipe clamp (A) and high pressure pipe (B).

3. Disconnect the fuel temperature sensor connector (A) and the inlet metering valve connector (B).

4. Remove the fuel feed hose (C).

5. Remove the return hose (D) connected with the injector.

6. Remove the return hose (E) connected with the fuel filter.

7. Unscrew 2 mounting bolts (A) at the side of the high pressure pump bracket.

8. Unscrew 2 mounting bolts (B) at the side of the cylinder block .

9. Remove the rubber cover (B) from the high pressure pump sprocket.

10. Rotate the sprocket (C) in order to meet the fixing hole of the sprocket (A) and the fixing hole (B) of the timing

case.
Fix the sprocket (C) to the timing case by using 2 bolts(I) of the SST (No.:OK552 131 003)