Repair Procedures: Installation

WARNING:

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.
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.

Fig 1: Low Pressure Fuel Hose Quick-Connector & High Pressure Fuel Pipe

Courtesy of HYUNDAI MOTOR CO.

CAUTION:

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.

CAUTION:

CAUTION:

CAUTION:

When tightening the installation bolts of the high pressure fuel pump, tighten the bolts in 1/2 turns (0.5 turns) sequentially after tightening them by hand sequentially.

CAUTION:

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.

CAUTION:

Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

CAUTION:

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.

Fig 2: O-Ring, High Pressure Fuel Pump & Protrusion
Courtesy of KIA MOTORS AMERICA, INC.