Hyundai Santa Fe (2006 year). Manual — part 478
FL -522
FUEL SYSTEM
CAUTION
• 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.
FUEL DELIVERY SYSTEM-DIESEL
FL -523
SCHEMATIC DIAGRAM
E61F31CB
High Pressure Fuel Line
Low Pressure Fuel Line
Fuel Return Line
High Pressure
Pump
Fuel Filter
Fuel Tank
Common Rail
Injector
Rail Pressure
Regulator Valve
ECM
Low Pressure Fuel Pump
Fuel Pressure
Regulator Valve
EFQG701A
COMPONENTS
●
LOW PRESSURE FUEL SYSTEM COMPONENTS
FUEL PUMP
The fuel pump is either an electric fuel pump with pre-filter,
or a gear-type fuel pump. The pump draws the fuel from
the fuel tank and continually delivers the required quantity
of fuel in the direction of the high-pressure pump.
FUEL FILTER
Inadequate filtering can lead to damage at the pump com-
ponents, delivery valves, and injector nozzles. The fuel
filter cleans the fuel before it reaches the high-pressure
pump, and thereby prevents premature wear at the pump’s
sensitive components.
FL -524
FUEL SYSTEM
●
HIGH PRESSURE FUEL SYSTEM COMPONENTS
HIGH PRESSURE FUEL PUMP
The high-pressure pump pressurizes the fuel to a system
pressure of up to 1,600bar. This pressurized fuel then
passes through a high-pressure line and into the tubular
common rail.
COMMON RAIL (HIGH PRESSURE ACCUMULATOR)
Even after an injector has taken fuel from the rail in order to
inject it, the fuel pressure inside the rail remains practically
constant. This is due to the accumulator effect arising from
the fuel’s inherent elasticity. Fuel pressure is measured
by the rail pressure sensor and maintained at the desired
level by the pressure-control valve.
INJECTORS
The nozzles of these injectors open when the solenoid
valve is triggered and permit the flow of fuel. They in-
ject the fuel directly into the engine’s combustion chamber.
The excess fuel which was needed for opening the injec-
tor nozzles flows back to the tank through a collector line.
The return fuel from the fuel pressure control valve and
from the low-pressure stage is also led into this collector
line together with the fuel used to lubricate the high-pres-
sure pump.
HIGH PRESSURE PIPE
These High Pressure Pipes carry the high-pressure fuel.
They must therefore be able to permanently withstand the
maximum system pressure and, during the pauses in in-
jection, the sometimes high-frequency pressure fluctua-
tions which occur. They are therefore manufactured from
steel tubing.
Normally, they have an outside diameter of about 6.35mm
and an internal diameter of about 3.0mm. The injection
lines between the common rail and the injectors must all be
of the same length. The differences in length between the
common rail and the individual injectors are compensated
for by using slight or pronounced bends in the individual
lengths of tubing. Nevertheless, the injection lines should
be kept as short as possible.
FUEL DELIVERY SYSTEM-DIESEL
FL -525
FUEL TANK
REMOVAL
E0CEE39C
1.
Turn ignition switch OFF and disconnet the negative
(-) battery cable.
2.
Remove the 2nd seat (Refer to group "BD" in this
Shop Manual).
3.
Open the carpet (A) for the fuel pump and the carpet
(B) for the sub fuel sender.
A
B
SCMFL6635D
4.
Remove the fuel pump service cover (A) and the sub
fuel sender service cover (B).
A
SCMFL6636D
B
SCMFL6637D
5.
Disconnect the fuel pump connector (A), the fuel feed
tube quick - connector (B), the fuel return tube quick -
connector (C) and the sub fuel sender connector (D).
A
C
B
SCMFL6638D
D
SCMFL6639D
6.
Lift the vehicle and support the fuel tank with a jack.
7.
Remove the muffler assembly and the propeller shaft
(4WD). (Refer to group "EM" and "DS" in this Shop
Manual.)
8.
Disconnect the fuel filler hose (A).
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