Hyundai Sonata: Fuel Delivery System / 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. 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 GDS after completion of “Release Residual Pressure in Fuel Line” work.
3.
Remove the intake manifold.
(Refer to Engine Mechanical System - "Intake Manifold")
4.
Disconnect the injector connectors (A) and the rail pressure sensor connector (B).
5.
Remove the high pressure fuel pipe (C).
6.
Remove the engine oil gauge.
7.
Remove the installation bolt (D), and then remove the delivery pipe and injector assembly from the engine.

Installation
   
Do not use already used injector fixing clip again.
   
Do not reuse the support disc.
Do not reuse the injector rubber washer.
Do not reuse the combustion seal.
   
Install the component with 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 injector O-ring.
Do not use already used injector O-ring again.
   
Do not use already used bolt again.
   
When insert the injector, be careful not to damage the injector tip.
1.
Install in the reverse order of removal.

Delivery pipe mounting bolt:
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
High pressure fuel pipe mounting nut:
26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft)

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High Pressure Fuel Pump Repair procedures
Removal     Whenever the high pressure fuel pump, fuel pipe, deliverypipe, or injector is removed immediately after shutting offthe engine, an injury may be caused by the rele ...

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