2012 Kia Sorento 3.5L V6 Fuel Delivery System 3.5L

2012 Kia Sorento EX
2012-13 ENGINE Fuel Delivery System - 3.5L - Sorento
2012-13 ENGINE
Fuel Delivery System - 3.5L - Sorento
COMPONENTS AND COMPONENTS LOCATION

COMPONENTS LOCATION
Fig. 1: Identifying Fuel Delivery System Components Location

Courtesy of KIA MOTORS AMERICA, INC.
REPAIR PROCEDURES
Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

viernes, 21 de julio de 2017 10:15:43
10:15:40 a. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
2012 Kia Sorento EX
FUEL PRESSURE TEST
1. Release the residual pressure in fuel line (Refer to "RELEASE RESIDUAL PRESSURE IN FUEL
LINE" ).
CAUTION: When removing the fuel pump relay, a Diagnostic Trouble Code
(DTC) may occur. Delete the code with the GDS after completion
of "Release Residual Pressure in Fuel Line" work.
2. Install the Special Service Tool (SST).

1. Disconnect the fuel feed tube from the delivery pipe.
CAUTION: 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 fuel feed tube and
the fuel delivery pipe (Refer to illustration below) .
Fig. 2: Identifying Special Service Tool

3. Inspect fuel leakage on connections among the fuel feed tube, the delivery pipe, and the SST
components with IG ON.
4. Measure Fuel Pressure.
1. Start the engine and measure the fuel pressure at idle.
Fuel Pressure: 379.5 kPa (3.87 kgf/cm2 , 55.0 psi)
NOTE: If the fuel pressure differs from the standard value, repair or
replace the related part (Refer to FUEL PRESSURE CHART.
FUEL PRESSURE CHART

viernes, 21 de julio de 2017 10:15:40 a. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
2012 Kia Sorento EX
Fuel Pressure Cause Related Part

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
NOTE: If the gauge reading should not be held, repair or replace the
related part (Refer to FUEL PRESSURE CHART.
FUEL PRESSURE CHART

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.

LINE").
6. Test End
1. Remove the Special Service Tool (SST) from the fuel feed tube and the delivery pipe.
2. Connect the fuel feed tube and the delivery pipe.
RELEASE RESIDUAL PRESSURE IN FUEL LINE
CAUTION: 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.
1. Turn the ignition switch OFF and disconnect the battery (-) cable.
2. Remove the fuel pump relay (A).

2012 Kia Sorento EX
Fig. 3: Identifying Fuel Pump Relay

3. Connect the battery (-) cable.

4. Start the engine and let idle, and then turn the ignition switch OFF after the engine has stopped on its
own.
5. Disconnect the battery (-) cable, and then install the fuel pump relay (A).
6. Connect the battery (-) cable.
7. Delete the Diagnostic Trouble Code (DTC) related the fuel pump relay with the GDS.
FUEL TANK
REPAIR PROCEDURES
Removal
LINE" ).
2. Remove the rear seat (Refer to "SEAT " ).
3. Remove the fuel pump service cover (A).

2012 Kia Sorento EX
Fig. 4: Identifying Fuel Pump Service Cover

NOTE: The wiring in between the fuel pump and the sub fuel sender is
fastened to the vehicle. So please separate it before removing the fuel
pump service cover in accordance with the procedures below.
1. Remove the sub fuel sender cover and disconnect the sub fuel
sender connector (Refer to "SUB FUEL SENDER" ).
2. Release the wiring clips (A) under the carpet.
Fig. 5: Identifying Wiring Clips

4. Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B).
5. Disconnect the fuel feed tube quick connector (C).

2012 Kia Sorento EX
Fig. 6: Identifying Fuel Feed Tube Quick Connector

6. Remove the sub fuel sender service cover (A).
Fig. 7: Identifying Sub Fuel Sender Service Cover

7. Disconnect the sub fuel sender connector (A).
Fig. 8: Identifying Sub Fuel Sender Connector

8. Lift the vehicle and support the fuel tank with a jack.
2012 Kia Sorento EX
9. Remove the center muffler assembly (Refer to "INTAKE AND EXHAUST SYSTEM " ).
10. Remove the propeller shaft (Refer to "PROPELLER SHAFT ASSEMBLY " .
11. Remove the protector (A).
Fig. 9: Identifying Protector

12. Disconnect the fuel filler hose (A).
Fig. 10: Identifying Fuel Filler Hose

13. Disconnect the ventilation hose quick-connector (A).

2012 Kia Sorento EX
Fig. 11: Identifying Ventilation Hose Quick-Connector

14. Disconnect the vapor tube quick-connector (A) and the ventilation tube quick-connector (B).
Fig. 12: Identifying Vapor Tube Quick-Connector And Ventilation Tube Quick-Connector
15. Remove the brake line (A) bracket.
Fig. 13: Identifying Brake Line Bracket

16. Remove the fuel tank from the vehicle after removing the fuel tank bands (A).
2012 Kia Sorento EX
Fig. 14: Identifying Fuel Tank Band

Installation
1. Installation is reverse of removal.
Fuel tank band installation nut:
39.2 ~ 54.0 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
FUEL PUMP
REPAIR PROCEDURES
Removal
LINE" ).
3. Remove the fuel pump service cover (A).
Fig. 15: Identifying Fuel Pump Service Cover

2012 Kia Sorento EX
NOTE: The wiring in between the fuel pump and the sub fuel sender is
fastened to the vehicle. So please separate it before removing the fuel
pump service cover in accordance with the procedures below.
1. Remove the sub fuel sender cover and disconnect the sub fuel
sender connector (Refer to "SUB FUEL SENDER" ).
2. Release the wiring clips (A) under the carpet.
Fig. 16: Identifying Wiring Clips

4. Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B).
5. Disconnect the fuel feed tube quick connector (C) and the vapor tube quick-connector (D).
Fig. 17: Identifying Fuel Pump Connector And Fuel Tank Pressure Sensor Connector
6. Remove locking ring (A) by using the special service tool (B).

2012 Kia Sorento EX
Fig. 18: Identifying Fuel Pump Locking Ring & Protector

7. Disconnected the suction tube (A) at the bottom of the fuel pump, and then remove the fuel pump
from the fuel tank.
Fig. 19: Identifying Suction Tube


2012 Kia Sorento EX
Fig. 20: Identifying Fuel Pump Assembly, Locking Ring And O-Ring
Installation
CAUTION: Be careful of fuel pump direction when installing (Refer to the

groove in the FUEL TANK).
SUB FUEL SENDER

REPAIR PROCEDURES
Removal
LINE" ).
3. Remove the fuel pump (Refer to "FUEL PUMP"), and then disconnect the suction tube (A) at the
bottom of the fuel pump.

2012 Kia Sorento EX
Fig. 21: Identifying Suction Tube

4. Remove the sub fuel sender service cover (A).
Fig. 22: Identifying Sub Fuel Sender Service Cover

5. Disconnect the sub fuel sender connector (A).

6. Disconnect the vapor tube quick-connector (B).
Fig. 23: Identifying Sub Fuel Sender Connector And Vapor Tube Quick-Connector
7. Remove locking ring (A) by using the special service tool (B).

2012 Kia Sorento EX
Fig. 24: Identifying Fuel Pump Locking Ring & Protector

8. Remove the fuel pump from the fuel tank.
Fig. 25: Identifying Sub Fuel Sender, Locking Ring And O-Ring
Installation
CAUTION: Be careful of sub fuel sender direction when installing (Refer to

the groove in the FUEL TANK.)

2012 Kia Sorento EX
FILLER-NECK ASSEMBLY
REPAIR PROCEDURES
Removal
1. Remove the protector (A).
Fig. 26: Identifying Protector

2. Remove the rear-LH wheel, tire, and the inner wheel house.
3. Disconnect the fuel filler hose (A).
Fig. 27: Identifying Fuel Filler Hose

4. Disconnect the ventilation hose quick-connector (A).

2012 Kia Sorento EX
Fig. 28: Identifying Ventilation Hose Quick-Connector

5. Remove the filler-neck assembly from the vehicle after removing the bracket mounting nuts (A).
Fig. 29: Identifying Bracket Mounting Nuts

Installation
Filler-neck assembly bracket installation nut :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
ACCELERATOR PEDAL
REPAIR PROCEDURES
Removal
1. Turn the ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the accelerator position sensor connector (A).

2012 Kia Sorento EX
3. Remove the installation nuts (B), and then remove the accelerator pedal module.
Fig. 30: Identifying Accelerator Position Sensor Connector

Fig. 31: Identifying Installation Nuts

Installation
Accelerator pedal module installation nut:
16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
DELIVERY PIPE
REPAIR PROCEDURES
Removal
1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
LINE" ).

2012 Kia Sorento EX
3. Remove the surge tank (Refer to "INTAKE AND EXHAUST SYSTEM " ).
4. Disconnect the injector [Bank 1] connector (A).
NOTE: The injector [Bank 2] connector was disconnected when removing the
surge tank.
5. Remove the delivery pipe installation bolts (B).
Fig. 32: Identifying Delivery Pipe Installation Bolts

6. Remove the installation nuts (A), and then remove the delivery pipe & injector assembly from the
engine.
Fig. 33: Identifying Installation Nuts


2012 Kia Sorento EX
Fig. 34: Identifying Delivery Pipe & Injector Assembly

Installation
Delivery pipe installation bolt:
8.8 ~ 11.8 N.m (0.9 ~ 1.2 kgf.m, 6.5 ~ 8.7 lb-ft)


2012 Kia Sorento 3.5L V6 Fuel Delivery System 3.5L

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2012 Kia Sorento 3.5L V6 Fuel Delivery System 3.5L

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2012 Kia Sorento EX

2012-13 ENGINE Fuel Delivery System - 3.5L - Sorento

Fuel Delivery System - 3.5L - Sorento

COMPONENTS AND COMPONENTS LOCATION

Fig. 1: Identifying Fuel Delivery System Components Location

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

FUEL PRESSURE TEST

2. Install the Special Service Tool (SST).

CAUTION: There may be some residual pressure even after "Release

Fig. 2: Identifying Special Service Tool

Fuel Pressure: 379.5 kPa (3.87 kgf/cm2 , 55.0 psi)

FUEL PRESSURE CHART

Fuel Pressure Cause Related Part

FUEL PRESSURE CHART

3. Turn the ignition switch OFF.

RELEASE RESIDUAL PRESSURE IN FUEL LINE

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 3: Identifying Fuel Pump Relay

3. Connect the battery (-) cable.

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 4: Identifying Fuel Pump Service Cover

Fig. 5: Identifying Wiring Clips

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 6: Identifying Fuel Feed Tube Quick Connector

6. Remove the sub fuel sender service cover (A).

Fig. 7: Identifying Sub Fuel Sender Service Cover

7. Disconnect the sub fuel sender connector (A).

Fig. 8: Identifying Sub Fuel Sender Connector

Fig. 9: Identifying Protector

12. Disconnect the fuel filler hose (A).

Fig. 10: Identifying Fuel Filler Hose

13. Disconnect the ventilation hose quick-connector (A).

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 11: Identifying Ventilation Hose Quick-Connector

15. Remove the brake line (A) bracket.

Fig. 13: Identifying Brake Line Bracket

Fig. 14: Identifying Fuel Tank Band

1. Installation is reverse of removal.

Fuel tank band installation nut:

39.2 ~ 54.0 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)

Fig. 15: Identifying Fuel Pump Service Cover

Fig. 16: Identifying Wiring Clips

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 18: Identifying Fuel Pump Locking Ring & Protector

Fig. 19: Identifying Suction Tube

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

1. Installation is reverse of removal.

CAUTION: Be careful of fuel pump direction when installing (Refer to the

SUB FUEL SENDER

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 21: Identifying Suction Tube

4. Remove the sub fuel sender service cover (A).

Fig. 22: Identifying Sub Fuel Sender Service Cover

5. Disconnect the sub fuel sender connector (A).

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 24: Identifying Fuel Pump Locking Ring & Protector

8. Remove the fuel pump from the fuel tank.

1. Installation is reverse of removal.

CAUTION: Be careful of sub fuel sender direction when installing (Refer to

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

1. Remove the protector (A).

Fig. 26: Identifying Protector

Fig. 27: Identifying Fuel Filler Hose

4. Disconnect the ventilation hose quick-connector (A).

Afinacion de Motor y Diagnostico,OBDII,VW,Audi 044 664 252 34 69

Fig. 28: Identifying Ventilation Hose Quick-Connector

Fig. 29: Identifying Bracket Mounting Nuts