1
- Facing the front of the car, the underhood fuse box is located on the right hand side, between the battery and the fender.
Hyundai Accent High Pressure Fuel Pump Replacement
The high pressure fuel pump on the Hyundai GDI engine boosts the fuel pressure from the average 65 PSI put out by the tank-mounted fuel pump so that it is high enough that it can be injected into a cylinder that's already at the top of its compression stroke, on the order of 2,000 PSI.
It is mandatory that the fuel pressure in the lines must be relieved before attempting work on any component of the fuel system.
Step-by-step instructions
1
Remove the engine cover
- Grasp the engine cover by the front edge.
- Give it a firm yank upward.
1
Disconnect the fuel pressure regulator electrical connector
- Press the locking tab on the fuel pressure regulator's electrical connector and unplug it.
2
Open the fuse box
- Press the tab on the front of the fuse box.
- And release the tab on the rear side of the fuse box.
2
- Grab the rear edge of the cover.
- Yank it upward.
2
Remove the fuel feed tube quick connector
- There will almost certainly be a small amount of residual pressure in the line, so spread a shop rag under the intake and high pressure lines.
- Disconnect the quick connect fitting.
- In this particular car the plastic release had deteriorated and basically disintegrated when it was attempted to be used. A fitting tool was used instead to accomplish the same goal.
- Disconnect the line.
- On reassembly, be sure to check the low pressure fuel hose quick-connector 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.
3
Disable the fuel pump
- You can remove the fuel pump fuse or the fuel pump relay; either one will accomplish your purpose.
- Fuel pump fuse
- Fuel pump relay
3
- The engine cover has been removed.
3
Disconnect the high pressure fuel line
- Using a 19 mm open end or tubing wrench, unscrew the high pressure fuel line from the high pressure fuel pump.
- On reassembly, be sure to install the high pressure fuel pipe with the specified torque (19.5 ~ 23.9 lb-ft).
4
- In this example, we are pulling the fuse rather than the relay, but again, either will do the job.
- Using the fuse puller found in the fuse box, remove the 15A fuel pump fuse and set it aside.
4
Remove the mounting bolts
- The high pressure fuel pump is under significant spring pressure, so the two bolts securing it must be loosened evenly to prevent damage to the housing surface.
- Use a 10 mm socket with a short extension to remove the bolts according to the instructions on the following pages.
5
Start the car
- Put the key in the ignition and start the car. There will usually be enough residual pressure in the line to allow the car to start.
5
- Start with one of the bolts.
- Turn it a half turn.
6
Run the car until the engine dies
- Depending how long it's been since the car was run last, there may be quite a bit of pressure in the lines, which can let the car run for as much as three minutes, so be patient and let the car idle until it dies on its own.
- Turn the car off and remove the key.
6
- Move to the other bolt.
- Turn it 1/2 turn.
7
- Repeat the previous two steps until the tension on the bolts has been relieved. At that point you can remove them both.
- When tightening the installation bolts of the high pressure fuel pump, tighten the bolts alternately in small steps (1/2 turn) after first hand tightening them.
- Final torque on the bolts is 9.4 ~ 10.9 lb-ft. Most non-professional torque wrenches aren't very accurate below 15 ft/lbs, so if possible use a wrench calibrated in in/lbs, 113 ~ 131 lb-in.
8
Remove the high pressure fuel pump
- The high pressure fuel pump can now be lifted off the valve cover.
9
Remove the roller tappet
- This is easiest done with a magnetic pickup tool, but it can be removed using your finger inserted into the roller tappet and pull up on it.
- 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.
Conclusion
To reassemble your device, follow these instructions in reverse order.
During reinstallation, apply engine oil to the O-ring of the high pressure fuel pump, the roller tappet, and the protrusion. Also apply engine oil to the groove on the location where the protrusion is installed.
Because fuel leak may cause fire, securely Inspect leakage of all fuel line connection parts at engine start condition.
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