Repair procedures: Installation

WARNING:

Be sure to check the low pressure fuel hose quick-connector (A) is completely connected to the high pressure fuel pump un confirmation 'click' sound is heard.

Fig 1: Checking Low Pressure Fuel Hose Quick-Connector
Courtesy of HYUNDAI MOTOR AMERICA
Be sure to re-check the low pressure fuel hose is completely connected to the high pressure fuel pump by pulling it after connecting.

Install the clamp cover (A) to tighten the quick-connector completely.

Fig 2: Installing Clamp Cover
Courtesy of HYUNDAI MOTOR AMERICA
Be sure to install the high pressure fuel pipe (B) with the specified torques.

Fig 3: Identifying High Pressure Fuel Pipe
Courtesy of HYUNDAI MOTOR AMERICA
Securely inspect leakage of all fuel line connection parts at engine start condition.

CAUTION:

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.

CAUTION:

Do not reuse the used bolt.

CAUTION:

Do not reuse the used high pressure fuel pipe.

CAUTION:

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.

CAUTION:

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.

CAUTION:

Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

CAUTION:

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.

Fig 4: Identifying O-Ring, Roller Tappet And Protrusion

G09789515

Courtesy of HYUNDAI MOTOR AMERICA

Install in the reverse order of removal.
NOTE: Use the special service tool [SST No.: 09314-3Q100 or 09314-27130] to install the high pressure fuel pipe.

Fig 5: Identifying Special Service Tool
Courtesy of HYUNDAI MOTOR AMERICA

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)