Hyundai Sonata: Engine Control System / Injector Repair procedures
| 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”
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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.
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| 1. |
Turn the ignition switch OFF and disconnect the battery negative (-) cable. |
| 2. |
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - “Release Residual Pressure in Fuel Line”)
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When removing the fuel pump relay, a Diagnostic Trouble Code
(DTC) may occur. Delete the code with the GDS after completion of
“Release Residual Pressure in Fuel Line” work. |
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| 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. 
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| • |
Do not reuse the used injector fixing clip. |
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| • |
Install the component with the specified torques. |
| • |
Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. |
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| • |
Apply engine oil to the injector O-ring. |
| • |
Do not reuse the used injector O-ring. |
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| • |
Do not reuse the used bolt. |
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| • |
When inserting the injector, be careful not to damage the injector tip. |
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| • |
Do not reuse the support disc. |
| • |
Do not reuse the injector rubber washer. |
| • |
When replacing the rubber washer, the steal plate (A) part
should be faced the cylinder installation part and the rubber plate (B)
part should be faced the injector body part. |
|
| • |
Do not reuse the combustion seal.
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|
| 1. |
Install in the reverse order of removal. |
The injector combustion seal should be replaced new one to prevent leakage after removing the injector.
| 1. |
Remove the combustion seal (A) with a wire cutter. 
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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 using a clean cloth.
Any coking of the injector sealing surface must be carefully removed with a brass-wire brush. 
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The surfaces of the new sealing ring must be clean and free of grease. |
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| 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. 
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| 4. |
To size the sealing ring the injector is first introduced
into the sizing tool (A) (SST No.: 09353-2B000) and then pressed and at
the same time rotated 180° into the sizing tool. 
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| 5. |
Pull the injector out of the sizing tool by turning it in the reverse direction to that used for the press-in process.
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Check that the seal ring has not been damaged during assembly to 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. |
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| 6. |
Check the combustion seal (A) installation. 
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Description
Purge Control Solenoid Valve (PCSV) is installed on the surge
tank and controls the passage between the canister and the intake
manifold. It is a solenoid valve and is open when the ...
Injector Schematic Diagrams
Purge Control Solenoid Valve (PCSV) Description and Operation