Hyundai Santa Cruz: Fuel Delivery System / High Pressure Fuel Pump

- Removal

1. Release the residual pressure in fuel line. (Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line")

2.Turn the ignition switch OFF and disconnect the negative (-) battery terminal.

3. Remove the engine cover.(Refer to Engine Mechanical System - "Engine Cover")

4.Disconnet the ignition coil connector (A).

5. Remove the headcover foam (B).

6.Remove the high pressure pump foam (A).

7.Disconnect the fuel pressure regulating valve connector (A).

8.Disconnet the fuel feed tube quick-connector (B).

• Pull the cover (B) of fuel feed tube quick-connector (A) by it in the direction of arrow.

• Disconnect the fuel feed tube quick-connector (B) by pulling it in the direction of arrow after pushing the quick-connector button (A).

9.Remove the air cleaner.(Refer to Engine Mechanical System - "Air Cleaner")

10. Remove the intercooler inlet hose.(Refer to Engine Mechanical System - "Intercooler")

11.Loosen the high pressure fuel pipe flange nut (A, B) using the SST (09314-L1100).

Tightening Torque : 29.4 - 35.3 N.m (3.0 - 3.6 kgf.m, 21.7 - 26.0 lb-ft)

12. Loosen the function block mounting bolt (A).

Tightening torque :9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

13. Remove the high pressure fuel pump (A), after loosening the mounting bolts.

Tightening torque :12.7 - 14.7 N·m (1.3 - 1.5 kgf·m, 9.4 - 10.8 lb·ft)

1.Install in the reverse order of removal.

• Unscrew in turns the two bolts in small steps (0.5 turns). When one of the two bolts is fully unscrewed while the other bolt (A) still intact, the housing surface of the cylinder head may be broken due to tension of the pump spring.

• Pull the cover (B) of fuel feed tube quick-connector (A) by it in the direction of arrow.

• Disconnect the fuel feed tube quick-connector (B) by pulling it in the direction of arrow after pushing the quick-connector button (A).

• Use the SST (09314-L110) and spaner torque wrench (27mm) to install the high pressure fuel pipe.

• Do not reuse the high pressure fuel pipe.

• Be careful not to transform the shape of the high pressure fuel pipe.

• Torque wrench should not be tilt when you tighten the nut.

• Follow the order and the tightening torque when you assemble.

• Inspect fuel leakage after high pressure fuel pipe assembly.

• Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the crankshaft. Otherwise the installation bolts may break due to the tension on the pump spring.

• Do not reuse the bolt.

• Install the component to the specified torques.

• 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.