Kia 353202G720 High Pressure Fuel Pump

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Apply engine oil to the high-pressure pump 0-ring and set the pump on the cylinder head.

Inspect the fuel pump inlet strainer for contamination. If it's dirty, try cleaning the strainer with some clean solvent and an old toothbrush. If the strainer is too dirty to be cleaned while it's installed, remove it from the fuel pump/fuel level sending unit and try cleaning it again. If you still can't clean it adequately, replace it.

Drain any residual gasoline from the fuel pump/fuel level sending unit, then place it on a clean workbench in a well-ventilated areCheck the strainer for clogging and replace it if necessary.

Verify that there is fuel in the fuel tank and that the fuel pump actually runs. When turning the ignition switch to ON, a brief whirring noise should emanate for about two seconds as the pump activates and pressurizes the system. For models without a Schrader valve, you'll require a fuel pressure gauge, a tee-fitting, short sections of approved fuel hose, and appropriate hose clamps. After relieving the system fuel pressure, disconnect the cable from the negative battery terminal. On Sephia and Spectra models, locate the fuel filter on the firewall and trace the hose to the fuel rail, then disconnect the fuel supply hose. On Sportage models, locate the supply line at the left end of the front fuel rail and trace it back to the threaded fitting below the brake master cylinder. Integrate your fuel pressure gauge between the disconnected fuel supply hose and the fuel rail. After reconnecting the negative battery terminal and turning on the ignition, the gauge should display pressure. For checking the operation of the fuel pressure regulator, monitor the gauge when the vacuum hose from the regulator is disconnected. The pressure should increase by 3 to 10 psi. On models with a Schrader valve, after connecting the fuel pressure gauge to the fuel rail test port, activate the ignition switch and note the pressure on the gauge. If it's low, inspect the fuel supply hose, replace the fuel filter, and subsequently the fuel pump or regulator as needed. If high, replace the regulator. Once testing is completed, ensure the negative battery terminal is reconnected, and start the engine to check for fuel leaks.

Remove the cover from the lower part of the pump assembly and pull the pump out of the cover. Remove the rubber insulators from both ends of the pump and the fuel pump inlet filter from the pump. If replacing the fuel pressure regulator, remove it from the fuel pump cover, install new O-rings on the new fuel pressure regulator, and then proceed to install the new filter, regulator, or sending unit on the fuel pump.

Remove the access cover screws and remove the cover, then disconnect the fuel supply line and suction line quick-connect fittings from the pump, remove the bolts from the fuel pump mounting flange and remove the pump assembly from the fuel tank.