Hyundai Santa Fe (2006 year). Manual — part 481
FL -534
FUEL SYSTEM
6.
Unscrew the mounting bolts (A) and remove the high
pressure pump (B).
B
A
A
A
EFQG080A
C
A
B
Fuel Pressure
Regulator Valve
A : To Fuel Tank
(Return Line)
B : From Fuel Tank
C : To Common Rail
SCMFL6141L
INSTALLATION
E6B56913
1.
Install the high pressure fuel pump according to the
reverse order of "REMOVAL" procedure.
NOTE
When installing the high pressure pipe, apply the
specified tightening torques to the flange nuts of the
high pressure pipe side and the common rail side
with SST (Refer to below table).
Item
Dimension
SST No.
Flange Nut (HP
Pump Side)
14 mm (0.551 in)
09314-27110
Flange Nut
(Common Rail
Side)
17 mm (0.669 in)
09314-27120
High pressure fuel pump mounting bolts: 19.6 ~ 26.5
N·m (2.0 ~ 2.7 kgf·m, 14.5 ~ 19.5 lbf·ft)
High pressure pipe flange nuts (Common Rail
↔
HP Pump): 24.5 ~ 28.4 N·m (2.5 ~ 2.9
kgf·m, 18.1 ~ 20.1 lbf·ft)
FUEL DELIVERY SYSTEM-DIESEL
FL -535
COMMON RAIL
DESCRIPTION
EDCDAA09
The common rail stores the fuel at high pressure. At the
same time, the pressure oscillations which are generated
due to the high-pressure pump delivery and the injection
of fuel are damped by the rail volume. This common rail
is common to all cylinders, hence its name "common rail".
Even when large quantities of fuel are extracted, the com-
mon rail maintains its inner pressure practically constant
from the moment the injector opens.
In order to comply with the wide variety of engine installa-
tion conditions, the common rail with its flow limiters and
the provistions for attaching rail pressure sensor, fuel pres-
sure control valve, and pressure limiter valve is available
in a number of different designs.
The available common rail volume is permanently filled
with pressurized fuel. The compressibility of the fuel re-
sulting from the high pressure is utilized to achieve the ac-
cumulator effect. When fuel leaves the rail for injection, the
pressure variations resulting from the pulsating fuel supply
from the high-pressure pump are compensated for.
REMOVAL
E0F2CC99
WARNING
• Common
Rail
Fuel
Injection
System
is
subject to extremely high pressure (Approxi-
mately 1,600 bar)
• Never perform any work on injection system
with engine running or within 30 seconds af-
ter the engine stops.
• Always pay attention to safety precaution.
• Ensure the absolute cleanliness.
• It is not recommended to remove the injectors
without any notice.
1.
Disconnect the rail pressure sensor connector (A) and
rail pressure regulator valve connector (B).
C
A
E
E
F
D
B
EFQG082A
2.
Disconnect the high pressure pipe (C) connecting the
injectors with the common rail.
3.
Disconnect the high pressure pipe (D) connecting the
common rail with the high pressure fuel pump.
4.
Unscrew the two mounting bolts (E) and remove the
common rail (F).
EFQG083A
INSTALLATION
EDD55345
1.
Install the common rail according to the reverse order
of "REMOVAL" procedure.
NOTE
When installing the high pressure pipe, apply the
specified tightening torques to the flange nuts of the
injectors, the high pressure pipe, and the common
rail side with SST (Refer to below table).
Item
Dimension
SST No.
Flange Nut
(Injector Side)
Flange Nut (HP
Pump Side)
14 mm (0.551 in)
09314-27110
Flange Nut
(Common Rail
Side)
17 mm (0.669 in)
09314-27120
· Common rail mounting bolts: 19.6 ~ 26.5 N·m
(2.0 ~ 2.7 kgf·m, 14.5 ~ 19.5 lbf·ft)
· High pressure pipe flange nuts (Injectors
↔
Common
Rail): 24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
· High pressure pipe flange nuts (Common
Rail
↔
HP Pump): 24.5 ~ 28.4 N·m (2.5 ~
2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
FL -536
FUEL SYSTEM
INJECTOR
DESCRIPTION
EE4DD145
The start of injection and the injected fuel quantity are
adjusted by electrically triggered injectors. These injec-
tors supersede the nozzle-and-holder assembly (nozzle
and nozzle-holder). Similar to the already existing nozzle-
holder assemblies in direct-injection (DI) diesel engines,
clamps are preferably used for installing the injectors in the
cylinder head. This means that the Common Rail injectors
can be installed in already existing DI diesel engines with-
out major modifications to the cylinder head.
EFQG101A
REMOVAL
E99E9BCE
WARNING
• Common
Rail
Fuel
Injection
System
is
subject to extremely high pressure (Approxi-
mately 1,600 bar)
• Never perform any work on injection system
with engine running or within 30 seconds af-
ter the engine stops.
• Always pay attention to safety precaution.
• Ensure the absolute cleanliness.
• It is not recommended to remove the injectors
without any notice.
1.
Disconnect the injector connector (A).
B
A
C
EFQG084A
2.
After removing the clip (B), disconnect the retun hose
(C) from the injectors
3.
Disconnect the high pressure pipe (A) connecting the
injectors with the common rail.
A
EFQG085A
4.
Rotate the lever (A) clockwise and pull it upward.
EFQG086A
FUEL DELIVERY SYSTEM-DIESEL
FL -537
5.
Unscrew the clamp tightening bolt (A) and pull the in-
jector upward with the "Injector Remover" and the "In-
jector Remover Adapter" (Refer to "SPECIAL SER-
VICE TOOL" section).
A
EFQG087A
Fuel Inlet
Connector
Injector
EFQG088A
INSTALLATION
E63E0B78
1.
Install the injector according to the reverse order of
"REMOVAL" procedure.
NOTE
When installing the injector, MUST REPLACE the
O-ring (A) and apply a grease to that.
A
EFQG089A
NOTE
When installing the high pressure pipe, apply the
specified tightening torques to the flange nuts of the
injectors and the common rail side with SST (Refer
to below table).
Item
Dimension
SST No.
Flange Nut
(Injector Side)
14 mm (0.551 in)
09314-27110
Flange Nut
(Common Rail
Side)
17 mm (0.669 in)
09314-27120
· Injector clamp mounting bolts: 24.5 ~ 28.4 N·m
(2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
· High pressure pipe flange nuts (Injectors
↔
Common
Rail): 24.5 ~ 28.4 N·m (2.5 ~ 2.9 kgf·m, 18.1 ~ 20.1 lbf·ft)
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