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

Kia Rio 2017-2024 YB Service Manual / Engine Control / Fuel System / Fuel Delivery System

Components and components location

Components Location

Fuel Tank & Filler-Neck Assembly

1. Fuel Tank
2. Fuel Pump
3 Fuel Pump Plate Cover
4. Fuel Filler Hose
5. Leveling Tube
6. Vapor Tube (Canister → Intake Manifold)

7. Vapor Hose (Canister → Fuel Tank)
8. Vapor Hose (Canister → Air Filter)
9. Vapor Hose (Air Filter → Atmosphere)
10. Fuel Tank Band
11. Filler-Neck Assembly

Fuel Pump

1. Head Assembly
2. Fuel Pressure Regulator
3. Fuel Filter
4. Fuel Pump Motor
5. Fre-Filter
6. Reservoir Cup

7. Fuel Sender
8. Fuel Pump Plate Packing
9. Fuel Pump Motor & Fuel Sender Connector
10. Fuel Feed Port
11. Fuel Feed Tube

Fuel pressure test (low pressure system)

Fuel Pressure Test (Low pressure system)

Release the residual pressure in fuel line.

(Refer to “Release Residual Pressure in Fuel Line” in this group).

When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the KDS/GDS after completion of “Release Residual Pressure in Fuel Line” work.

Install the Special Service Tool (SST).

(1)

Disconnect the low pressure fuel feed tube from the low pressure inlet of high pressure fuel pump.

There may be some residual pressure even after “Release Residual Pressure in Fuel Line” work, 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 low fuel feed tube and the low pressure inlet of high pressure fuel pump (Refer to the figure below).

3.	Inspect fuel leakage on connections among the low fuel feed tube, the low pressure inlet of high pressure fuel pump, and the SST components with IG ON.

Measure Fuel Pressure.

(1)

Start the engine and measure the fuel pressure at idle.

Fuel Pressure:

330 - 370kpa (3.36 - 3.77kgf/cm², 47.86 - 53.66 psi)

If the fuel pressure differs from the standard value, repair or replace the related part (Refer to the table below).

Fuel Pressure	Cause	Related Part
Too Low	Fuel filter clogged	Fuel Filter
Too Low	Fuel leakage	Fuel Pressure Regulator
Too High	Fuel pressure regulator valve 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 should 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)	Turn the ignition switch OFF.

5.	Release the residual pressure in fuel line (Refer to “Release Residual Pressure in Fuel Line”).

Test End

(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

1.	Turn the ignition switch OFF and disconnect the battery (-) terminal.

Remove the fuel pump fuse (A).

When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the KDS/GDS after completion of “Release Residual Pressure in Fuel Line” work.

3.	Connect the battery negative (-) terminal.

4.	Start the engine and let idle.

5.	Turn the ignition switch OFF after the engine has stopped on its own.

6.	Disconnect the battery negative (-) terminal, and then install the fuel pump fuse (A).

7.	Connect the battery negative (-) terminal.

8.	Delete the Diagnostic Trouble Code (DTC) related the fuel pump fuse with the KDS/GDS.

ISG OFF switch

Components and components location Components Description and operation Description The ISG OFF switch on the floor console can be used to deactivate the ISG function. ...

Fuel Tank

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

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