Introduction
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.
What you need
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Facing the front of the car, the underhood fuse box is located on the right hand side, between the battery and the fender.
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Press the tab on the front of the fuse box.
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And release the tab on the rear side of the fuse box.
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You can remove the fuel pump fuse or the fuel pump relay; either one will accomplish your purpose.
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Fuel pump fuse
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Fuel pump relay
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In this example, we are pulling the fuse rather than the relay, but again, either will do the job.
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Using the fuse puller found in the fuse box, remove the 15A fuel pump fuse and set it aside.
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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.
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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.
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Turn the car off and remove the key.
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Grasp the engine cover by the front edge.
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Give it a firm yank upward.
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Press the locking tab on the fuel pressure regulator's electrical connector and unplug it.
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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.
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Disconnect the quick connect fitting.
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Disconnect the line.
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Using a 19 mm open end or tubing wrench, unscrew the high pressure fuel line from the high pressure fuel pump.
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Use a 10 mm socket with a short extension to remove the bolts according to the instructions on the following pages.
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Repeat the previous two steps until the tension on the bolts has been relieved. At that point you can remove them both.
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The high pressure fuel pump can now be lifted off the valve cover.
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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.
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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.
