Question 1

How to relieve fuel system pressure and remove the high-pressure fuel pump on Hyundai Sonata?

Accepted Answer

To relieve the fuel system pressure, disconnect the cable from the negative battery terminal. Remove the air filter housing and disconnect the fuel pressure regulator valve electrical connector. Take out the ignition coil from cylinder number four and remove the canister purge control solenoid valve. Disconnect the fuel supply line quick disconnect fitting and use a special tool to remove the nut from the high pressure fuel pump and delivery pipe. Remove the junction block and then the high-pressure fuel pipe. Be cautious and discard the pipe, obtaining a new one. Unscrew the fuel pump mounting bolts evenly and discard them, obtaining new ones. Remove the high-pressure fuel pump from the cylinder head. Rotate the engine until the lifter for the high pressure pump is at the lowest point. Apply engine oil to the high-pressure pump O-ring and set the pump on the cylinder head. Install new bolts and tighten them. The remainder of the installation is the reverse of removal.

Question 2

How to remove and install Fuel Level Sensor and Fuel Pump on Hyundai Sonata?

Accepted Answer

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.

Question 3

How to check Fuel Pump and fuel pressure on Hyundai Sonata?

Accepted Answer

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.

Question 4

How to replace the fuel pump/fuel level sending unit assembly from the fuel tank on Hyundai Sonata?

Accepted Answer

Once you have removed the fuel pump/fuel level sensor from the fuel tank, you can replace the entire assembly, or you can disassemble it and replace the fuel inlet strainer, the fuel pump or the fuel level sensor. Remove the fuel pump/fuel level sensor assembly from the fuel tank. Drain any residual gasoline from the fuel pump/fuel level sensor, then place the fuel pump/fuel level sensor on a clean workbench. Make sure that the work area is well ventilated, because there will be gasoline evaporating from the pump/sensor for a while. Check the filter for clogging. If in doubt, replace it. The fuel level sensor can be replaced on 1999 through 2005 models. Unclip it from the main assembly. Other components such as the pressure regulator and the pump may be serviceable with individual aftermarket parts available from a local parts store. Reassembly is the reverse of disassembly. Install the fuel pump/fuel level sensor in the fuel tank. For 2011 and later models, depress the fuel pump/sensor locking tabs at the top and remove the top of the assembly. Disconnect the fuel feed line quick-disconnect connector. Remove the mounting clip and disconnect the fuel line. Depress the reservoir cup locking tabs and remove the reservoir cup (outer housing). Disconnect the ground cable, then remove the assist pump and the fuel pressure regulator. Depress the fuel filter locking tabs and separate the fuel filter from the fuel pump. Remove the fuel filter. Installation is the reverse of removal.

Genuine Hyundai Sonata Fuel Pump

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