Hyundai 31111-1G500 Pump-Fuel

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Access the fuel pump module. On 1999 through 2005 models, it is located at the rear of the fuel tank under the vehicle (raise the vehicle and support it securely on jackstands). On later models, it's under a cover in the trunk floor. Remove the cover and disconnect the fuel pump electrical connector. Relieve the fuel system pressure and remove the fuel tank cap. Disconnect the cable from the negative battery terminal. Disconnect the fuel lines from the top of the fuel pump unit. Remove the retaining bolts from the fuel pump/fuel level sensor mounting flange. Carefully lift the fuel pump/fuel level sensor assembly from the fuel tank. Inspect the fuel pump inlet strainer for contamination. If it's dirty, try cleaning the strainer with some clean solvent and an old toothbrush. If the strainer is too dirty to be cleaned while it's installed, remove it from the fuel pump/fuel level sensor and try cleaning it again. If you still can't clean it adequately, replace it. Installation is the reverse of removal.

Check the fuel tank and listen for the fuel pump when the ignition is on. If there's no sound, inspect the EFI fuse and fuel pump relay. If voltage is present at the fuel pump connector, the pump is faulty. If not, the PCM may be defective. To test fuel pressure, use a fuel pressure gauge and T-fitting. For return-type systems, the pump should run for two seconds when the ignition is on. High pressure indicates a restricted fuel return hose or line. Low pressure suggests a restricted fuel filter or supply hose. A substantial pressure drop after five minutes may indicate a leaking injector or faulty check valve. For returnless systems, low pressure indicates obstructions in the fuel supply hose and line, while high pressure requires replacing the fuel pump/regulator. After testing, relieve the fuel pressure, remove the gauge, and start the engine to check for leaks.

Some models have an anti-theft radio; ensure you have the activation code before disconnecting the battery.

Make sure the camshaft lobe is at its base circle and lubricate the pump roller with engine oil. Align the tab on the roller body with the groove in the bore of the valve cover and install the roller. Lubricate the pump O-ring and set the pump onto the valve cover, then tighten the bolts alternately and evenly until the pump is seated.

Connect a remote starter switch or detach the fuel outlet hose from the carburetor and direct it into a container while cranking the engine. If fuel is emitted in spurts, the pump is operating properly.

Yes, the fuel level sending unit can be replaced on 1999 through 2005 models. It can be unclipped from the main assembly.

Begin by relieving fuel system pressure and disconnecting the negative battery cable.

First, relieve the system fuel pressure and disconnect the negative battery cable. Then, depending on the model year, either reconnect the fuel pump connector or reinstall the fuel pump fuse. For older models, locate the fuel filter and remove the cable tie that attaches the fuel pressure line to the fuel return line. Unplug the brake fluid level sensor electrical connector from the master cylinder. Put a shop rag around the fuel line retaining bolt on top of the fuel filter and remove the bolt to disconnect the fuel line. Connect a fuel pressure gauge to the fuel filter (or fuel rail for newer models) in place of the fuel line. Reconnect the negative battery cable, start the engine, and check for leaks. Measure the fuel pressure and compare it to the specified measurement. Finally, disconnect the vacuum line from the fuel pressure regulator - the fuel pressure should immediately increase. Measure the fuel pressure again and compare it to the specified measurement.

Install new bolts and tighten them.