Hyundai Coupes/Sedans 1994-1998 Repair Guide

Fuel Pump

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See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: Cutaway view of the electric fuel pump



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Fig. Fig. 2: Fuel tank and fuel pump assembly-Excel and 1994-95 Elantra



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Fig. Fig. 3: Fuel tank and fuel pump assembly-Scoupe



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Fig. Fig. 4: Fuel tank and fuel pump assembly-Sonata



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Fig. Fig. 5: Fuel tank and fuel pump assembly-Accent



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Fig. Fig. 6: Fuel tank and fuel pump assembly-Tiburon and 1996-98 Elantra

REMOVAL & INSTALLATION



See Figures 7, 8, 9, 10 and 11

  1. Relieve the fuel system pressure.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the fuel tank drain plug and drain the fuel into an approved container.
  6.  
  7. Remove the fuel tank from the vehicle.
  8.  
  9. Label, disconnect and plug the vapor and fuel hoses at the pump.
  10.  
  11. Label and disconnect the electrical harness at the pump.
  12.  
  13. Loosen the fuel pump mounting bolts.
  14.  
  15. Remove the fuel pump from the tank and discard the gasket.
  16.  

To install:
  1. Install the fuel pump using a new gasket. Tighten mounting bolts to 1-2 ft. lbs. (3-4 Nm).
  2.  
  3. Connect the electrical harness at the pump.
  4.  
  5. Connect the vapor and fuel hoses at the pump. Tighten fuel hose connections to 22-29 ft. lbs. (29-39 Nm).
  6.  
  7. Install the fuel tank and fuel drain plug.
  8.  
  9. Lower the vehicle.
  10.  
  11. Fill tank with fuel and check for proper fuel pump operation.
  12.  

OPERATIONAL TESTING





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Fig. Fig. 7: Fuel pump test connector location-Excel



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Fig. Fig. 8: Fuel pump test connector location-Scoupe



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Fig. Fig. 9: Fuel pump test connector location-Sonata



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Fig. Fig. 10: Fuel pump test connector location-Accent



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Fig. Fig. 11: Fuel pump test connector location-Elantra and Tiburon

  1. Check the fuse.
  2.  
  3. Check all wiring connections.
  4.  
  5. Check the fuel pump relay. If the engine starts when the ignition switch is turned to START , but stops when it is turned to ON , the relay is faulty.
  6.  

It is sometimes hard to hear the fuel pump operate. It may be easier to hear the pump operate by removing the fuel cap and listening at the fuel filler nozzle.

  1. Jumper fuel pump test connector and the fuel pump should operate. If the pump fails to operate when the jumper is connected, the pump is faulty.
  2.  

PRESSURE TESTING



See Figures 12, 13 and 14



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Fig. Fig. 12: Connecting the fuel pressure test gauge on vehicles with fuel block connection on filter-except Sonata



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Fig. Fig. 13: Connecting the fuel pressure test gauge on vehicles with banjo type connection on filter-except Sonata



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Fig. Fig. 14: Connecting the fuel pressure test gauge-Sonata

  1. Relieve fuel system pressure.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Disconnect the inlet fuel hose from the fuel filter.
  6.  
  7. Connect a fuel pressure gauge with the appropriate adapters.
  8.  
  9. Connect the negative battery terminal.
  10.  
  11. Apply battery voltage to the fuel pump test connector located in the engine compartment, which will energize the fuel pump. With pressure applied, check for fuel leakage at the gauge. If no leaks are present, continue with the test procedure.
  12.  
  13. Start the engine and run at curb idle speed.
  14.  
  15. Measure the fuel pressure and compare to specifications.
  16.  
  17. Locate and disconnect the vacuum hose running to the fuel pressure regulator. Plug the end of the hose and record the fuel pressure again. The fuel pressure should have increased approximately 10 psi.
  18.  
  19. If the pressure readings were not at the desired specifications, perform the following diagnostic procedure:
    1. If fuel pressure is too low, check for a clogged fuel filter, a defective fuel pressure regulator or a defective fuel pump, any of which will require replacement.
    2.  
    3. If fuel pressure is too high, the fuel pressure regulator is defective and will have to be replaced, or the fuel return is bent or clogged. If the fuel pressure reading does not change when the vacuum hose is disconnected, the hose is clogged or the valve is stuck in the fuel pressure regulator and it will have to be replaced.
    4.  
    5. Stop the engine and check for changes in the fuel pressure gauge. It should not drop. If the gauge reading does drop, watch the rate of drop. If fuel pressure drops slowly, the likely cause is a leaking injector which will require replacement. If the fuel pressure drops immediately after the engine is stopped, the check valve in the fuel pump isn't closing and the fuel pump will have to be replaced.
    6.  

  20.  
  21. Relieve fuel system pressure.
  22.  
  23. Remove the fuel pressure gauge.
  24.  
  25. Apply battery voltage to the fuel pump check connector. Check for leaks.
  26.  

 
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