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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 repair work right after engine stops.
  1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  2. Release the residual pressure in fuel line (Refer to "FUEL PUMP " in this group).
    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.
  3. Remove the intake manifold (Refer to "Intake And Exhaust System ").
  4. Disconnect the injector connectors (A) and the rail pressure sensor connector (B).
  5. Remove the high pressure fuel pipe (C).
  6. Remove the engine oil gauge.
  7. Remove the installation bolt (D), and then remove the delivery pipe and injector assembly from the engine.
    Fig 1: Identifying Injector And Rail Pressure Sensor Connector
    G08807124Courtesy of HYUNDAI MOTOR AMERICA
    Fig 2: Identifying High Pressure Fuel Pipe
    G08807125Courtesy of HYUNDAI MOTOR AMERICA
    Fig 3: Identifying Injector And Delivery Pipe
    G08807126Courtesy of HYUNDAI MOTOR AMERICA


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 repair work right after engine stops.
  1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  2. Release the residual pressure in fuel line (Refer to "RELEASE RESIDUAL PRESSURE IN FUEL LINE " in this group).
    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.
  3. Remove the air cleaner and the air intake hose (Refer to "Intake And Exhaust System ").
  4. Disconnect the fuel pressure regulator valve connector (A).
  5. Disconnect the fuel feed tube quick-connector (B).
    Fig 1: Identifying Fuel Pressure Regulator Valve And Feed Tube Quick Connector
    G08807127Courtesy of HYUNDAI MOTOR AMERICA
  6. Remove the high pressure fuel pipe.
    1. Remove the installation nut (A) from the high pressure fuel pump with the special service tool [SST No.: 09314-3Q100 or 09314-27130]
      Fig 2: Identifying Special Service Tool
      G08807128Courtesy of HYUNDAI MOTOR AMERICA
    2. Remove the installation nut (B) from the delivery pipe with the special service tool [SST No.: 09314-3Q100 or 09314-27130]
      Fig 3: Identifying Delivery Pipe And Installation Nut
      G08807129Courtesy of HYUNDAI MOTOR AMERICA
    3. Disconnect the engine coolant temperature sensor connector.
    4. Remove the function block (C), and then remove the high pressure fuel pipe.
      Fig 4: Identifying Function Block
      G08807130Courtesy of HYUNDAI MOTOR AMERICA
  7. Remove the installation bolts (D), 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 5: Identifying High Pressure Fuel Pump Installation Bolts
    G08807131Courtesy of HYUNDAI MOTOR AMERICA
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