Hyundai Genesis: Fuel Delivery System / Repair procedures

Fuel Pressure Test

1.	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 turn up. Delete the code with the GDS after completion of “Release Residual Pressure in Fuel Line” work.

2.

Install the Special Service Tool (SST). (1) Disconnect the fuel feed tube from the high pressure fuel pump. There may be some residual high pressure even after “Release Residual Pressure in Fuel Line” work, so must cover the high pressure line connection part with a shop towel or a cloth to prevent residual fuel from spilling out before removing any high pressure fuel part. Then release pressure by carefully removing connection part. Otherwise, it may result in the injury by high temperature and pressure fuel.  (2) Install the special service tool for measuring the fuel pressure in between the fuel feed tube and the high pressure fuel pump (Refer to the figure below).

3.	Inspect the fuel line and SST connection parts for any leakage with the ignition ON.

4.

Measure Fuel Pressure. (1) Start the engine and measure the fuel pressure at idle. Fuel Pressure: 343 ~ 598 kPa (3.5 ~ 6.1 kgf/cm?, 49.8 ~ 86.7 psi) If the fuel pressure differs from the standard value, repair or replace the related part. (2) Stop the engine, and then check for the change in the fuel pressure gauge reading. Standard Value: The gauge reading should be maintained for about 5 minutes after the engine stops. If the gauge reading should not be maintained, repair or replace the related part (Refer to the table below). Fuel Pressure (After Engine Stops) Cause Related Part Fuel Pressure Drops Slowly Leakage on injector Injector Fuel Pressure Drops Immediately Check valve of fuel pump stuck open Fuel Pump (3) Turn the ignition switch OFF.

5.	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 turn up. Delete the code with the GDS after completion of “Release Residual Pressure in Fuel Line” work.

6.	Test End (1) Remove the Special Service Tool (SST) from the fuel feed tube and the high pressure fuel pump. (2) Connect the fuel feed tube to the high pressure fuel pump.

Release Residual Pressure in Fuel Line

Whenever the high pressure fuel pump, fuel pipe, delivery pipe, or injector is removed immediately after the engine shuts off, an injury may be caused by the release of highly pressurized fuel. Release the residual pressure in the high pressure fuel line by referring to the "Residual fuel pressure release procedure" below before removing any high pressure fuel system components.

Wear safety glasses and fuel resistant gloves.

1.	Turn the ignition off and disconnect the battery negative cable.

2.	Remove the fuel pump fuse (A).

3.	Disconnect the electrical connector from the high pressure fuse pump.

4.	Reconnect the battery negative cable.

5.	Run the engine for about 20 seconds to lower the pressure in both the high or low pressure lines. The engine may shut off within the 20 second period. If not, turn the engine off.

6.	Proceed with the service or repair. Use cloth to cover opening and catch spills when opening up the high pressure system.

7.	Reinstall / re-connect all components in the reverse order of removal. Start engine and confirm proper operation, and make sure there are no fuel leaks.

8.	After completing, clear DTC(s) using GDS scan tool (The procedure described above will cause DTC to turn up.).

Troubleshooting

Troubleshooting     • Check the fuel pressure after replacing parts. (Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line") ...

Fuel Tank Repair procedures

Removal 1. Release the residual pressure in fuel line. (Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line") 2. Turn the ignition switch OFF and disconnect the negative ...

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