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.

Turn the ignition switch OFF and disconnect the battery negative (-) cable.
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.
Remove the pump foam (A).

Fig 1: Identifying Pump Foam
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the fuel pressure control valve connector (A) and the fuel feed tube quick-connector (B).

Fig 2: Identifying Fuel Pressure Control Valve And Fuel Feed Tube Quick-Connector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the intake manifold.
(Refer to "INTAKE MANIFOLD ")
Remove the injector foam (A).

Fig 3: Identifying Injector Foam
Courtesy of HYUNDAI MOTOR AMERICA
Remove the high pressure fuel pipe.
1. Remove the high pressure pipe flange nut in order of A, B with the special service tool [SST No.: 09314-3V100]
  
  Fig 4: Identifying Special Service Tool
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 5: Removing High Pressure Pipe Flange Nut Using Special Service Tool (1 Of 2)
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 6: Removing High Pressure Pipe Flange Nut Using Special Service Tool (2 Of 2)
  Courtesy of HYUNDAI MOTOR AMERICA
2. Remove the high pressure pipe bracket bolt (A).
  
  Fig 7: Identifying High Pressure Pipe Bracket Bolt
  Courtesy of HYUNDAI MOTOR AMERICA
3. Remove the function block installation bolt (A).
  
  Fig 8: Identifying Function Block Installation Bolt
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the installation bolts (A), and then remove the high pressure fuel pump (B) 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 9: Identifying High Pressure Fuel Pump And Installation Bolts
Courtesy of HYUNDAI MOTOR AMERICA