Hyundai Sonata: High Pressure Fuel Pump Repair procedures - Fuel Delivery System - Engine Control / Fuel SystemHyundai Sonata: High Pressure Fuel Pump Repair procedures

Removal
   
Whenever the high pressure fuel pump, fuel pipe, deliverypipe, or injector is removed immediately after shutting offthe engine, an injury may be caused by the release ofhighly pressurized fuel. Release the residual pressure inthe high pressure fuel line by referring to the "Residualfuel pressure release procedure" before removingany high pressure fuel system components.
1.
Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2.
Release the residual pressure in fuel line.
(Refer to the Fuel Delivery System - Repair Procedures - "Release Residual Pressure in Fuel Line").
   
When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur.
Delete the code with the GDS after completion of “Release Residual Pressure in Fuel Line” work.
3.
Disconnect the fuel pressure control valve connector (A) and the fuel feed tube quick-connector (B).

   
Open the clamp cover (B) before disconnect the quick connector. (If the clip is applied)

   
When removing the quick-connnector 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.

4.
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.: 09314-3Q100]

(2)
Disconnect the engine coolant temperature sensor connector.
(3)
Remove the function bolck installation bolt (C).

5.
Remove the installation bolts (D), and then remove the high pressure fuel pump from the cylinder head assembly.
   
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.

Installation
   
Be sure to check the low pressure fuel hose quick-connector (A) is completely connected to the high pressure fuel pump until a confirmation 'click' sound is heard.
Be sure to re-check the low pressure fuel hose is completely connected to the high pressure fuel pump by pulling it after connecting.
Be sure to install the high pressure fuel pipe (B) with the specified torques.
Because fuel leak may cause fire, securely Inspect leakage of all fuel line connection parts at engine start condition.

   
Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.
   
Do not reuse the used bolt.
   
Do not reuse the used high pressure fuel pipe.
   
When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5 turns) after tightening them with hand-screwed torque.
   
Install the component with the specified torques.
First hand-tighten the fasteners fully until they are not fastened any more in order to have them inserted in place and then completely tighten to the specified torque using a torque wrench.
If not tightening the bolts or nuts in a straight line with the mating bolt holes or fittings, it may cause a fuel leak due to broken threads.
   
Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
   
Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove on the location where the protrusion (C) is installed.

1.
Install in the reverse order of removal.
   
Use the special service tool [SST No.: 09314-3Q100] to install the high pressure fuel pipe.


High pressure fuel pump installation bolt:
12.8 ~ 14.7 N.m (1.3 ~ 1.5 kgf.m, 9.4 ~ 10.9 lb-ft)
High pressure fuel pipe installation nut:
26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft)
High pressure fuel pipe function block installation bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

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