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Home >> Genesis >> 2021 >> G80 3.5T, AWD >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Control System - 3.5L >> Injector >> Repair Procedures >> Removal >> GDI Injector
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GDI Injector

  1. 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 diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.
  2. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  3. Remove the engine cover.

    (Refer to Engine Mechanical System - "ENGINE COVER ")

  4. Drain engine coolant by loosening the drain plug.

    (Refer to Engine Mechanical System - "COOLANT ")

  5. Remove the reservoir tank.
    1. Disconnect the reservoir tank water hose (A).
    2. Disconnect the over flow hose (B).
    3. Remove the reservoir tank (C).

    Tightening torque: 

    7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)

    G15557060Courtesy of HYUNDAI MOTOR AMERICA
  6. After loosening the mounting bolts, then remove the high pressure fuel pump cover and form (A).

    Tightening torque: 

    9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

    G15557061Courtesy of HYUNDAI MOTOR AMERICA
  7. Remove the RH injector form.
    G15557062Courtesy of HYUNDAI MOTOR AMERICA
  8. After loosening the high pressure fuel pipe function block mounting bolt (C) and the flange nuts (B), remove the high pressure fuel pipe (A).

    Tightening torque: 

    [Function block] 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

    [Flange nut] 29.4 - 34.3 N.m (3.0 - 3.5 kgf.m, 21.7 - 25.3 lb-ft)

    G15557063Courtesy of HYUNDAI MOTOR AMERICA
  9. Disconnect the fuel line quick-connector (A) and the vapor quick-connector (B) connected to the purge control solenoid valve.
    G15557064Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • Pull the cover (B) of fuel feed tube quick-connector (A) by it in the direction of arrow.
      G15557065Courtesy of HYUNDAI MOTOR AMERICA
    • Disconnect the fuel feed tube quick-connector (B) by pulling it in the direction of arrow after pushing the quick-connector button (A).
    G15557066Courtesy of HYUNDAI MOTOR AMERICA
  10. Remove mounting bolts and connectors, space wiring bracket (A) and remove ignition coil form.

    Tightening torque: 

    9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

    G15557067Courtesy of HYUNDAI MOTOR AMERICA
  11. Remove the LH injector form.
  12. After loosening the high pressure fuel pipe function block mounting bolt (C) and the flange nuts (B), remove the high pressure fuel pipe (A).

    Tightening torque: 

    [Function block] 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

    [Flange nut] 29.4 - 34.3 N.m (3.0 - 3.5 kgf.m, 21.7 - 25.3 lb-ft)

    G15557068Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • After removing the high pressure fuel pipe, seal the inside of GDI fuel rail/connection (A) to prevent contamination.

    [Bank 1] 

    G15557069Courtesy of HYUNDAI MOTOR AMERICA

    [Bank 2] 

    G15557070Courtesy of HYUNDAI MOTOR AMERICA
  13. Loosen the mounting bolt (A), and remove the delivery pipe & injector assembly.

    Tightening torque: 

    18.7 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.8 - 17.3 lb-ft)

    [Bank 1] 

    G15557071Courtesy of HYUNDAI MOTOR AMERICA

    [Bank 2] 

    G15557072Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • Spray the compressed air to remove the foreign matter inside the injector hole (A) before removing the GDI fuel rail.

    [Bank 1] 
    G15557073Courtesy of HYUNDAI MOTOR AMERICA

    [Bank 2] 
    G15557074Courtesy of HYUNDAI MOTOR AMERICA
  14. Disconnect the injector conductors (A).
    G15557075Courtesy of HYUNDAI MOTOR AMERICA
  15. Remove the injector (A) in the direction of the arrow.
    G15557076Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • If the GDI injector is stuck in the cylinder head when removing the GDI fuel rail, seal the inside/inlet (A) of the GDI injector to prevent contamination.
    • Spray the compressed air to remove the foreign matter inside the injector hole (B) before removing the GDI fuel rail.
    G15557077Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • If the injector adheres to the cylinder head, use the special Service Tool (SST No.: 09351-C3700).
    • Be careful not to bend the injector when removing it.
    G15557078Courtesy of HYUNDAI MOTOR AMERICA
  16. After removing the injector, check whether any part is separated or foreign material remains inside the GDI fuel rail injector cup (A). If foreign material is found, immediately remove it.
G15557079Courtesy of HYUNDAI MOTOR AMERICA
G15557080Courtesy of HYUNDAI MOTOR AMERICA
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