Hyundai i-30: Fuel Delivery System / High Pressure Fuel Pump

Hyundai i30 (PD) 2018-2024 Service Manual / Engine Control / Fuel System / Fuel Delivery System / High Pressure Fuel Pump

Specifications
Specification
Items
Specification
High Pressure Fuel Line
bar
20 - 350
MPa
2 - 35
kgf/cm²
20.4 - 356.9
psi
290.1 - 5076.3

Repair procedures
Removal
  
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.
1.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
2.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
3.
Remove the engine cover.
(Refer to Engine Mechanical System - "Engine Cover")
4.
Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
5.
Disconnect the high pressure fuel pump connector (A) and then disconnect the fuel feed tube quick-connector (B).

  
Open the clamp cover (A) before disconnecting the quick connector (if the clip is applied).

  
When removing the quick-connector by using a clip removing tool (A), be careful not to damage the plastic clip (B).
If the clip is damaged, fuel line leakage may occur due to poor connection.

6.
Remove the high pressure fuel pipe.
(Refer to Fuel Delivery System - "Delivery Pipe")
7.
Remove the high pressure fuel pump (A).
Tightening Torque :
12.7 - 14.7 N.m (1.3 - 1.5 kgf.m, 9.4 - 10.8 lb-ft)

  
Unscrew in turn the two bolts in small steps (0.5 turns). If one of the two bolts is fully unscrewed while the other is installed, the housing surface of the cylinder head may get broken due to the tension on the pump spring.
Installation
  
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.
Keep away from foreign materials when assembling.
Do not reuse the bolt.
Do not reuse the high pressure fuel pipe.
When tightening the installation bolts of the high pressure fuel pump, pretighten the bolts by hand, and then fully tighten in turns in small steps (0.5 turns).
Install the component to the specified torques.
First, pretighten the fasteners by hand until they are not fastened anymore in order to have them inserted in place, and then using a torque wrench, fully tighten them to the specified torque.
If the bolts or nuts are not tightened in a straight line with the mating bolt holes or fittings, fuel leakage may occur 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 or 09314-27130] to install the high pressure fuel pipe.

    Delivery Pipe

    Repair procedures Removal    • 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...

    Clutch System

    ..

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