Hyundai Genesis: Engine Control System / Injector Repair procedures

Inspection
1.
Turn the ignition switch OFF.
2.
Disconnect the injector connector.
3.
Measure resistance between the injector terminals 1 and 2.
4.
Check that the resistance is within the specification.

Specification: Refer to “Specification”

Removal
   
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don’t do any repair work right after engine stops.
1.
Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2.
Release the residual pressure in fuel line (Refer to “Release Residual Pressure in Fuel Line” in this group).
   
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.
3.
Remove the delivery pipe & injector assembly (Refer to "Delivery Pipe" in this group).
4.
Remove the connector (A) and the fixing clip (B), and then separate the injector from the delivery pipe.

Installation

1.
Combustion seal
2.
Rubber washer
3.
Support disc
4.
O-ring
   
Do not reuse the used injector fixing clip.
   
Install the component with the specified torques.
Note that internal damage may occur if the component drops. In this case, use it after inspection.
   
Apply engine oil to the injector O-ring.
Do not reuse the used injector O-ring.
   
Do not reuse the used bolt.
   
When inserting the injector, be careful not to damage the injector tip.
   
Do not reuse the support disc.
Do not reuse the injector rubber washer.
When replacing the rubber washer, the rounded edge (A) should face the cylinder installation and the angulated edge (B) should face the injector body.

   
Do not reuse the combustion seal.
1.
To install, reverse the removal procedure.
Replacement
The injector combustion seal should be replaced with a new one one to prevent leakage after removing the injector.
1.
Remove the combustion seal (A) with a wire cutter.

   
Grip the sealing ring carefully, pull it to form a small loop and then cut it.
Be careful not to damage the surface of the valve sleeve with the wire cutter.
2.
Before the assembly of the sealing ring the groove must be cleaned with a clean cloth.
Any coking of the injector sealing surface must be carefully removed with a brass-wire brush.

   
The surfaces of the new sealing ring must be clean and free of grease.
3.
Place the seal installing guide (B) (SST No.: 09353-2B000) on the tip of the injector not to damage the injector tip (A).
Push the sealing ring (C) with thumb and index finger over the conical assembly tool until it snaps into the groove.
The complete assembly must not take longer than 2 to 3 seconds.

4.
To measure the size of the sealing ring, the injector is first inserted into the sizing tool (A) (SST No.: 09353-2B000) and then pressed and at the same time rotated 180° into the sizing tool.

5.
Pull the injector out of the sizing tool by turning it in the reverse direction to the one used for the press-in process.
   
Check that the seal ring has not been damaged during assembly by the injector and that no circumferential scratches are present.
Do not reuse the combustion seal.
The seal must be completely free of grease and oil.
6.
Check the combustion seal (A) installation.

Injector Schematic Diagrams
Circuit Diagram ...

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