Repair Procedures: Removal

WARNING:

In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any remedy work right after engine stops.

Turn the ignition switch OFF and disconnect the battery negative (-) cable.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "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.
Disconnect the fuel feed tube quick-connector (A) using a clip tool.
Disconnect the fuel pressure control valve-connector (B).

Fig 1: Fuel Feed Tube Quick-Connector And Fuel Pressure Control Valve-Connector
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
- Open the clamp cover (B) before disconnect the quick connector. (If the clip is applied)
Fig 2: Clamp Cover
Courtesy of HYUNDAI MOTOR AMERICA
CAUTION:
- When removing the quick-connector with the clip removing tool (A), be careful not to damage the plastic clip (B).
- If the clip is damaged, fuel line leak can be occurred due to a bad connection.
  
  Fig 3: Clip Removing Tool And Plastic Clip
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the intake manifold.
(Refer to Engine Mechanical System - "INTAKE MANIFOLD ")
Remove the high pressure fuel pipe.
1. Remove the bracket mounting bolt (A).
  
  Fig 4: High Pressure Fuel Pipe Bracket Mounting Bolt
  Courtesy of HYUNDAI MOTOR AMERICA
2. Remove the high pressure pipe flange nut (A, B) in order of A, B with the special service tool [SST No.: 09314-3V100 or 09314-27130]
3. Remove the high pressure pipe bracket bolt (C).
  
  Fig 5: High Pressure Pipe Flange Nut
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 6: High Pressure Pipe Bracket Bolt
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the installation bolts (A) and then remove the high pressure fuel pump from the cylinder head assembly.
CAUTION:
- Unscrew in turn the two bolts in small step (0.5 turns). In case of fully unscrewing one of the two bolts with the other bolt installed, the housing surface of the cylinder head may be broken because of tension of the pump spring.
Fig 7: High Pressure Fuel Pump Installation Bolts
Courtesy of HYUNDAI MOTOR AMERICA