Hyundai i-30: Engine Control System / Injector

Hyundai i30 (PD) 2018-2024 Service Manual / Engine Control / Fuel System / Engine Control System / Injector

Description and operation
Description
The GDI injector is similar to a standard injector, but sprays fuel at a much higher pressure directly into the combustion chamber and has a swirl disc to get the fuel swirling as it exits the nozzle. This aids in atomization of the fuel.
The ECM controls both the feed circuits (high side) to feed voltage to the injectors and the ground circuits (low side) to energize the injectors. Also, the feed for 2 injectors comes from the same driver set. As the ignition coils are paired with cylinders (1-4 and 2-3), the injectors are also set up in pairs.

Specifications
Specification
Item
Specification
Coil Resistance (Ω)
1.19 - 1.31 [20°C (68°F)]

Schematic diagrams
Circuit Diagram

Harness Connector

Repair procedures
Inspection
1.
Turn the ignition switch OFF.
2.
Disconnect the injector connector.
3.
Measure resistance between the injector terminals 1 and 2.
4.
Check that the resistance is within the specification.
Specification : Refer to "Specification"
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 negative (-) cable.
2.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
  
When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.
3.
Remove the delivery pipe & injector assembly.
(Refer to Fuel Delivery System - "Delivery Pipe")
4.
Disconnect the wiring connector and then separate the injector (A) from the delivery pipe (B).

Installation
1.
Install in the reverse order of removal.
  
Do not reuse the used bolt.
Do not reuse the used injector fixing clip.
Do not reuse the high pressure fuel pipe.
Do not reuse the combustion seal (A).

Be careful not to apply oil to combustion seal.
Do not reuse the O-ring (A), support disk (B), rubber washer (C).

When replacing the rubber washer, the steal plate part should be faced the cylinder installation part and the rubber plate part should be faced the injector body part.
Apply the engine oil to the injector O-ring.
When inserting the injector, be careful not to damage the injector tip.
Replacement
  
In order to prevent from oil leak, replacement of combustion seal should follow the below procedure.
1.
Remove the combustion seal (A).
  
Be careful not to damage the injector while remove the combustion seal.
Remove the combustion seal using a nipper.

2.
Before the assembly of the sealing ring the groove must be cleaned using a clean cloth.
3.
Install the combustion seal using a special service tool (SST No. : 09353-L1100).
(1)
Place the seal installing guide (A) (SST No.: 09353-2B000) on the tip of the injector not to damage the injector tip (B).

(2)
Install the combustion seal (A) to the seal installing guide.

(3)
Input the seal to A direction of the installer, and push it to B direction until it reaches the combustion seal installation area.
  
The complete assembly must not take longer than 2 to 3 seconds.

(4)
Install the compressor (A) and disconnect it after rotating 3-4 times to left and right direction.

(5)
Check the combustion seal (A) installation.

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