Hyundai i20 (GB) 2014-2023 Owner's Manual: High Pressure Fuel Pump Repair Procedures

1
Release the residual pressure in the fuel line. (Refer to Fuel System - "Fuel Line Residual Pressure Release".)
2
Turn the ignition switch to the OFF position and disconnect the negative (-) battery terminal.
3
Remove the high pressure fuel pipe. (Refer to Fuel Pipe - High Pressure Fuel Pipe)
4
Loosen the mounting bolts (A), then remove the high pressure fuel pump cylinder head assembly (B). High pressure fuel pump mounting bolt: 12.8 ~ 14.7 N·m
Caution
- Loosen the two bolts alternately in small steps (0.5 turn each). If one of the two bolts is fully loosened while the other is still installed, the cylinder head housing surface may be damaged by the pump spring tension.

NOTE

Before installing the high pressure fuel pump, set the roller plunger to its lowest position by turning the crankshaft. Otherwise, the mounting bolts may break due to pump spring tension.
Be careful to keep foreign objects out during assembly.
Do not reuse the bolt.
Do not reuse the high pressure fuel hose.
When tightening the high pressure fuel pump mounting bolts, tighten them alternately in small steps (0.5 turn each) after hand-tightening them.
Install the component to the specified torque.
First tighten the fasteners by hand until they are fully seated, then fully tighten to the specified torque using a torque wrench. If bolts or nuts are not aligned with their bolt holes or fittings, fuel leakage may occur due to thread damage.
Be aware that internal damage may occur if the component is dropped. If so, inspect it before use.
Apply engine oil to the pump O-ring (A), the high pressure fuel pump roller tappet (B) and the projection (C). Also apply engine oil to the groove in which the projection (C) is installed.

To install, perform the removal procedure in reverse order.
NOTE
- Use the special service tool [SST No. 09314-3Q100 or 09314-27130] to install the high pressure fuel pipe.

High Pressure Fuel Pump Repair Procedures