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 high pressure fuel pipe bracket installation bolt.
(Refer to "INTAKE & EXHAUST SYSTEM ")
Remove the intake manifold.
(Refer to "INTAKE & EXHAUST SYSTEM ")
Remove the pump foam (A).
[Bank 1]

Fig 1: Pump Foam (Bank 1)
Courtesy of HYUNDAI MOTOR AMERICA

[Bank 2]

Fig 2: Pump Foam (Bank 2)
Courtesy of HYUNDAI MOTOR AMERICA
Remove the injector foam (A).

Fig 3: Injector Foam
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the fuel feed tube quick-connector (A) with a clip removing tool.

Fig 4: Fuel Feed Tube Quick-Connector
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Open the clamp cover (B) before disconnecting the quick-connector. (If the clip is applied)

Fig 5: Clamp Cover
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: 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.

Fig 6: Clip Removing Tool And Plastic Clip
Courtesy of HYUNDAI MOTOR AMERICA
Remove the installation high pressure fuel pipe flange nut (A) from the high pressure fuel pipe with the special service tool [SST No.: 09314-3Q100 or 09314-27130].

Fig 7: Special Service Tool
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the fuel pressure regulator valve connector (B).
Remove the installation bolts (C), 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 8: High Pressure Fuel Pipe Flange Nut, Fuel Pressure Regulator Valve Connector And Installation Bolts

Courtesy of HYUNDAI MOTOR AMERICA

Fig 9: High Pressure Fuel Pipe Flange Nut, Fuel Pressure Regulator Valve Connector And Installation Bolts

Courtesy of HYUNDAI MOTOR AMERICA

Fig 10: High Pressure Fuel Pipe Flange Nut

Courtesy of HYUNDAI MOTOR AMERICA