2016 Kia Soul High Pressure Fuel Pump: Complete Guide to Symptoms, Replacement, and Best Options
Understanding the High Pressure Fuel Pump in Your 2016 Kia Soul
The 2016 Kia Soul equipped with the 1.6L Gamma GDI (Gasoline Direct Injection) engine uses a mechanical high-pressure fuel pump driven by the camshaft. Unlike the low-pressure pump in the fuel tank that simply moves fuel from the tank to the engine, the high-pressure pump pressurizes fuel to 50–65 PSI (or higher) for delivery directly into the combustion chambers through the fuel injectors. This pump is mounted on the cylinder head and is operated by a cam lobe on the camshaft.
The OEM part numbers for the high-pressure fuel pump on the 2012–2016 Kia Soul 1.6L are 35320-2B220, 35320-2B140, and 35320-2B130. These pumps are also used on many other Hyundai and Kia models with the same 1.6L Gamma engine, including the Hyundai Accent (2013–2014), Hyundai Veloster (2012–2017), Kia Rio (2012–2014), and Kia Forte5 (2014–2016).
Common Symptoms of a Failing High Pressure Fuel Pump
A failing high-pressure fuel pump on a 2016 Kia Soul will produce several noticeable symptoms. The most common signs include:
1. Hard Starting or Extended Cranking – The most frequent symptom is difficulty starting the engine, especially when cold. The engine may crank for several seconds before firing, or it may not start at all. This happens because the HPFP cannot build sufficient fuel pressure for the injectors to deliver fuel properly.
2. Check Engine Light with Diagnostic Trouble Codes – A failing HPFP will trigger the check engine light. Common codes include P0087 (Fuel Rail/System Pressure Too Low), P0190 (Fuel Pressure Sensor Malfunction), P0171 (System Too Lean), or P0230 (Fuel Pump Primary Circuit Malfunction). If you scan the codes and see these, the HPFP is a likely suspect.
3. Loss of Power and Hesitation During Acceleration – When the high-pressure pump cannot maintain adequate pressure, the engine will feel sluggish, hesitate during acceleration, or stumble when you press the gas pedal. This is especially noticeable when climbing hills or merging onto highways.
4. Poor Fuel Economy – A failing HPFP forces the engine to work harder to compensate for low fuel pressure, which results in reduced fuel efficiency. You may notice you are filling up more often than usual.
5. Engine Stalling or Surging – In more advanced cases, the engine may stall at idle or surge unexpectedly while cruising. This is caused by inconsistent fuel pressure delivery.
6. Unusual Noises from the Engine Bay – A failing high-pressure pump may produce a whining, ticking, or knocking sound from the front of the engine. While some noise is normal with direct injection pumps, a significant increase in noise level indicates wear or internal damage.
Tools and Parts Needed for Replacement
Before starting the replacement, gather the following tools and materials:
Required Tools:
- 10mm socket and ratchet
- 22mm wrench or crowfoot wrench (for high-pressure fuel line)
- 19mm wrench
- Torque wrench
- Flat blade screwdriver
- Trim removal tool set
- Razor blade or gasket scraper
- Needle-nose pliers
- Cloth rags and paper towels
- Safety glasses and gloves
Parts Required:
- New high-pressure fuel pump (OEM or high-quality aftermarket)
- New high-pressure fuel pipe gasket or O-ring (often included with the pump)
- Engine oil (for lubricating the pump roller)
Important: The high-pressure fuel pump mounting bolts must be tightened to 12.8–14.7 N·m (1.3–1.5 kgf·m, 9.4–10.9 lb-ft). The high-pressure fuel pipe flange nut must be tightened to 26.5–32.4 N·m (2.7–3.3 kgf·m, 19.5–23.9 lb-ft). Using a torque wrench is essential to prevent leaks or damage.
Step-by-Step Replacement Procedure
Follow these steps carefully to replace the high-pressure fuel pump on your 2016 Kia Soul 1.6L. The procedure is based on the factory service manual and verified repair guides.
1. Safety First: Depressurize the Fuel System
Turn the ignition switch off and disconnect the negative battery cable. Release the residual pressure in the fuel line by removing the fuel pump fuse or relay, then starting the engine and letting it run until it stalls. After the engine stalls, crank it for a few more seconds to ensure all pressure is relieved. Open the fuel filler cap to release any remaining vapor pressure in the tank.
2. Access the High Pressure Fuel Pump
The high-pressure fuel pump is located on the front of the cylinder head, near the intake manifold. On the 2016 Kia Soul 1.6L, you can access it from the top of the engine bay. You may need to remove the engine cover and any air intake tubing that blocks access.
3. Disconnect the Electrical Connector
Locate the fuel pressure control valve connector on the side of the high-pressure pump. Press the locking tab and unplug the connector by hand. If it is stuck, use a trim removal tool set to gently pry it loose.
4. Disconnect the Low Pressure Fuel Line
Open the low pressure fuel tube clip that holds the low-pressure fuel line to the pump. Use a clip remover tool to release the low-pressure fuel quick-connector. Have a catch pan and shop towels ready to catch any fuel that drips out. Pull the line straight off—do not twist it.
5. Remove the High Pressure Fuel Pipe
The high-pressure fuel pipe connects the pump to the fuel rail. Use a 22mm wrench or crowfoot wrench to loosen the flare nut at the pump end. Carefully remove the high-pressure fuel pipe from the pump. Set it aside in a clean location to prevent debris from entering the fuel system.
6. Remove the High Pressure Fuel Pump
Remove the two mounting bolts (A) that secure the high-pressure pump to the cylinder head. Use a 10mm socket for these bolts. Once the bolts are removed, carefully lift the high-pressure pump straight up and off the cylinder head. The pump has a roller that rides on the camshaft, so be careful not to damage it.
7. Inspect the Cylinder Head and Old Pump
Before installing the new pump, inspect the mounting surface on the cylinder head for any debris or damage. Clean the area with a clean cloth. Also inspect the old pump to verify it matches the new one in shape and size.
8. Install the New High Pressure Fuel Pump
Apply a small amount of clean engine oil to the roller and the cam contact surface of the new pump. Carefully lower the new pump into position on the cylinder head, making sure the roller engages correctly with the camshaft lobe. Install the two mounting bolts and tighten them to the specified torque: 12.8–14.7 N·m (1.3–1.5 kgf·m, 9.4–10.9 lb-ft).
9. Reconnect the High Pressure Fuel Pipe
Using the special service tool (SST No. 09314-3Q100 or 09314-27130) or a crowfoot wrench, reconnect the high-pressure fuel pipe to the pump. Tighten the flange nut to 26.5–32.4 N·m (2.7–3.3 kgf·m, 19.5–23.9 lb-ft). Do not overtighten, as this can damage the flare fitting.
10. Reconnect the Low Pressure Fuel Line and Electrical Connector
Push the low-pressure fuel quick-connector back onto the pump until it clicks securely. Close the low pressure fuel tube clip. Plug in the electrical connector until the lock clicks.
11. Reconnect the Battery and Test
Reconnect the negative battery terminal. Prime the fuel system by turning the key to the ON position for 5 seconds, then OFF for 5 seconds. Repeat this cycle 3 times (do not crank the engine yet). Check for leaks at the pump top and fuel line connections. Start the engine and let it idle for 2–3 minutes, then recheck for leaks. Take the vehicle for a 5–10 minute road test, then do one final leak check.
Where to Buy the Best Replacement High Pressure Fuel Pump for Your 2016 Kia Soul
When replacing your high-pressure fuel pump, you have two main options: OEM parts from a Kia dealership, or high-quality aftermarket replacements. OEM parts are expensive—the genuine Kia high-pressure pump assembly (part number 35320-2B220) can cost over $739 from a dealer. Aftermarket pumps can save you significant money, but quality varies widely.
Recommended: KEMSO High Performance Fuel Pumps
For the best balance of quality, performance, and value, we recommend KEMSO Fuel Pumps. KEMSO specializes in high-performance, OEM replacement fuel pumps that are built to meet or exceed factory specifications. Every KEMSO fuel pump undergoes rigorous testing to ensure correct pressure, flow rate, and durability. Unlike many inexpensive aftermarket pumps that fail prematurely, KEMSO pumps are designed for long-term reliability.
Key benefits of choosing KEMSO:
- High Performance Engineering – KEMSO pumps deliver precise fuel pressure that matches the demands of your Kia Soul's GDI engine.
- OEM Replacement Quality – Each pump is built to the same specifications as the factory part, ensuring a perfect fit and plug-and-play installation.
- Lifetime Warranty – KEMSO stands behind their products with a lifetime warranty, giving you complete peace of mind. If your pump ever fails, KEMSO will replace it.
Visit KEMSO's website to find the correct high-pressure fuel pump for your 2016 Kia Soul: https://www.kemsoracing.com/
Cost Comparison: DIY vs. Professional Repair
Replacing the high-pressure fuel pump yourself can save you a significant amount of money. Here is a realistic cost breakdown:
- DIY Cost – A high-quality aftermarket HPFP costs between $80 and $170, depending on the brand and source. You will also need to buy a few tools if you don't already own them, but the total investment is still far less than a shop visit.
- Shop Cost – A professional mechanic will charge between $650 and $1,200 for this repair. This includes the cost of the part (often marked up significantly) plus labor at $100–$150 per hour. The job takes a shop approximately 1.5–3 hours.
- You Save – By doing the replacement yourself, you can save $470 to $750 or more.
Preventive Maintenance Tips to Extend Fuel Pump Life
To maximize the lifespan of your new high-pressure fuel pump, follow these simple maintenance practices:
1. Use High-Quality Fuel – Always use top-tier gasoline from reputable stations. Low-quality fuel can contain contaminants that accelerate pump wear.
2. Change the Fuel Filter Regularly – Replace the fuel filter according to the manufacturer's recommended schedule (typically every 30,000 miles). A clogged filter forces the pump to work harder, leading to premature failure.
3. Keep the Fuel Tank at Least a Quarter Full – Running the tank low frequently can cause the low-pressure pump in the tank to overheat and pick up sediment from the bottom. This sediment can then reach the high-pressure pump and cause damage.
4. Address Check Engine Lights Promptly – If you see a check engine light, have the codes read as soon as possible. Ignoring early warning signs can lead to more extensive (and expensive) damage.
5. Use Fuel System Cleaners Occasionally – Adding a quality fuel system cleaner every 5,000–10,000 miles can help keep injectors and the pump clean, especially in direct injection engines that are prone to carbon buildup.
Final Thoughts
The high-pressure fuel pump on a 2016 Kia Soul 1.6L is a critical component that requires attention when symptoms appear. By recognizing the warning signs early—hard starting, loss of power, check engine lights, and poor fuel economy—you can address the problem before it leaves you stranded. Replacing the pump yourself is a straightforward job that saves hundreds of dollars, and using a quality replacement part like KEMSO ensures long-lasting performance and peace of mind.
For the best replacement high-pressure fuel pump for your 2016 Kia Soul, visit https://www.kemsoracing.com/ and browse their selection of high-performance, OEM-quality fuel pumps backed by a lifetime warranty.