Hyundai Kona: Fuel Delivery System / High Pressure Fuel Pump Repair procedures

Hyundai Kona (OS) 2018-2025 Service Manual / Engine Control / Fuel System / Fuel Delivery System / High Pressure Fuel Pump 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 negative (-) cable.

Release the residual pressure in fuel line.

(Refer to "Release Residual Pressure in Fuel Line" in this group)

•	When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after completion of "Release Residual Pressure in Fuel Line" work.

3.	Remove the intercooler inlet hoses & pipe. (Refer to Engine Mechanical System - "Intercooler")

4.	Remove the pump foam.

Disconnect the fuel pressure control valve connector (A) and the fuel feed tube quick-connector (B).

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

•	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.This may be the cause of the fire.

Remove the high pressure fuel pipe.

(1)	Remove the high pressure flange nut in order of (A,B) with the special service tool [SST No.: 09314-3Q100].

(2)	Disconnect the engine coolant temperature sensor connector.

(3)	Remove the function bolck installation bolt (C).

Remove the installation bolts (D), and then remove the high pressure fuel pump from the cylinder head assembly.

•	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.

Installation

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

•	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.

•	Be sure to install the high pressure fuel pipe (B) with the specified torques.

•	Because fuel leak may cause fire, securely Inspect leakage of all fuel line connection parts at engine start condition.

•	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.

•	Do not reuse the used bolt.

•	Do not reuse the used high pressure fuel pipe.

•	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.

•	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.

•	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.

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.

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)

High Pressure Fuel Pump Specifications

Specification Items Specification High Pressure Fuel Line bar 20 - 200 MPa 2 - 20 ...

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