VISUAL INSPECTION
Visually inspect all electrical wiring, looking for chafed, stretched, cut or pinched wiring. Ensure electrical connectors fit tightly and are not corroded. Ensure vacuum hoses are properly routed and are not pinched or cut, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article and VACUUM DIAGRAMS article. Also inspect air induction system for possible vacuum leaks.
FUEL PUMP TEST
Turn ignition off. Locate fuel pump check connector. See FUEL PUMP CHECK CONNECTOR LOCATOR table. On Accent, apply battery voltage to fuel pump check connector. see scheme 2 On all other models, apply battery voltage to fuel pump check connector terminal No. 9. see scheme 1 On all models, remove fuel tank filler cap and listen for fuel pump operation noise. Also pinch fuel hoses by hand and ensure fuel pressure can be felt.
| Application | Fuel Pump Check Connector Location |
|---|---|
| Except Accent | Left Side, Under The Dash |
| Accent | Engine Compartment Fuse/Relay Box |
FUEL PUMP CHECK CONNECTOR LOCATOR
Scheme 1
Scheme 2
- Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-152016-S27651135502003011300000). Disconnect negative battery terminal and reconnect fuel pump harness connector.
- Disconnect high-pressure fuel hose from fuel delivery pipe. Cover hose connection using rags to avoid spraying of fuel.
- Using Fuel Pressure Gauge Adapter (09353-38000), install fuel pressure gauge (09353-24100) to fuel delivery pipe. (Scheme 1)or (Scheme 2). Tighten fuel gauge adapter bolts to 18-26 ft. lbs. (24.4-35.3 N.m). Connect negative battery cable.
- Locate fuel pump check connector. See «FUEL PUMP CHECK CONNECTOR LOCATOR»(ref-152016-S19806883282003011300000) table. Apply battery voltage at fuel pump check connector terminal No. 9 to activate fuel pump. see scheme 1 Ensure no fuel leakage is present at pressure gauge or connection. If no leaks are present, start engine and allow it to idle. Go to next step.
- Disconnect vacuum hose from fuel pressure regulator, and plug hose end. Measure and record fuel pressure at idle. Reconnect vacuum hose, and again measure and record fuel pressure. See «REGULATED FUEL PRESSURE (AT IDLE)»(ref-152016-S09592029012003011300000) table. If fuel pressures are as specified, go to step 9. If fuel pressures are less than specified, go to next step. If fuel pressures are greater than specified, go to step 7. If fuel pressure does not change when regulator vacuum hose is connected and disconnected, go to step 8.
- Check for following conditions: Restricted fuel filter. Fuel pressure regulator leaking fuel to fuel return side. Leaking in-tank fuel pick-up hose. Low fuel pump discharge pressure. Repair or replace as necessary, and recheck fuel pressure. After repair, go to step 10.
- Check for sticking fuel pressure regulator, restricted or bent fuel return hose or pipe. Repair or replace fuel hoses or pipe, or replace fuel pressure regulator.
- Check for following conditions: Restricted or damaged vacuum hose. Restricted manifold vacuum port. Sticking or poorly seated fuel pressure regulator valve. Repair or replace as necessary, and recheck fuel pressure. After repair, go to step 10.
- If fuel pressures are as specified, stop engine and check for decrease in fuel pressure gauge. Fuel pressure should hold for approximately 5 minutes. If fuel pressure decreases slowly after engine is stopped, check for leaking injector. Replace as necessary. If fuel pressure decreases immediately after engine is stopped, fuel pump check valve is not working. Replace fuel pump. After repairs are completed, recheck fuel pressure and go to next step.
- After testing is completed, release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-152016-S27651135502003011300000). Disconnect fuel pressure gauge from adapter. Ensure hose connection is covered by shop towel to prevent fuel spray. Remove adapter bolts and adapter. Install NEW "O" ring and reinstall fuel line with original bolts and tighten fuel hose bolts to 18-26 ft. lbs. (24.4-35.3 N.m). Apply battery voltage to fuel pump check connector terminal No. 9. see scheme 1 Check for fuel leaks.
Engine Control Relay Test (Accent, Elantra & Tiburon)
- Locate and remove engine control relay, see «ENGINE CONTROL RELAY LOCATION»(ref-152016-S16430739242003011300000) table. Using fused jumper wire, apply battery voltage to relay terminal No. 2 (component side). (Scheme 3) Using second fused jumper wire, ground relay terminal No. 4 (component side). Go to next step.
- With relay energized, check for continuity between relay terminals No. 5 and 1 (component side). Continuity should be present until voltage is disconnected. If continuity is not as specified, replace engine control relay.
| Application | Engine Control Relay Location |
|---|---|
| Accent | Under Left Side Of Dash, Near Fuse Box |
| Elantra, Santa Fe & Tiburon | Engine Compartment Fuse/Relay Box |
| Sonata & XG350 | Right Side Of Instrument Panel In Center Support, Under Radio |
ENGINE CONTROL RELAY LOCATION
Scheme 3
Engine Control Relay Test (Santa Fe, Sonata & XG350)
Sonata 2.4L and XG350 are equipped with an 8-pin engine control relay. (Scheme 4) Sonata 2.7L is equipped with a 5-pin engine control relay. (Scheme 3) Engine control relay Information on Santa Fe is not available from manufacturer. Component testing information is not available from manufacturer.
Scheme 4
Fuel Pump Relay Test (Accent & Elantra)
- Locate and remove fuel pump relay, see «FUEL PUMP RELAY LOCATION»(ref-152016-S39063422442003011300000) table. Using fused jumper wire, apply battery voltage to relay terminal No. 5 (component side). (Scheme 5) Using second fused jumper wire, ground relay terminal No. 3 (component side). Go to next step.
- With relay energized, check for continuity between relay terminals No. 1 and 2 (component side). Continuity should be present until voltage is disconnected. If continuity is not as specified, replace fuel pump relay.
| Application | Fuel Pump Relay Location |
|---|---|
| Accent, Elantra, Santa Fe & Tiburon | Engine Compartment Fuse/Relay Box |
| Sonata & XG350 | Right Side Of Instrument Panel In Center Support, Under Radio |
FUEL PUMP RELAY LOCATION
Scheme 5
Fuel Pump Relay Test (Santa Fe, Sonata 2.7L & Tiburon)
Component testing information is not available from manufacturer.
Fuel Pump Relay Test (Sonata 2.4L & XG350)
On Sonata 2.4L and XG350, fuel pump relay and engine control relay are built into a single unit. See ENGINE CONTROL RELAY TEST (SANTA FE, SONATA & XG350) under ENGINE CONTROL RELAY.
Fuel Injector Inspection
- Warm up engine and allow it to idle. Using screwdriver or stethoscope, listen to each injector. Clicking sound should be heard. If no sound is heard, measure resistance of suspected fuel injector. See «FUEL INJECTOR RESISTANCE SPECIFICATIONS»(ref-152016-S23410429502003011300000) table. (Scheme 6) Replace injectors that do not meet specification. To replace fuel injectors, see FUEL DELIVERY PIPE & INJECTORS under FUEL SYSTEM in «REMOVAL, OVERHAUL & INSTALLATION»(ref-152037) article. If injectors are okay and no operational sound is heard, go to next step.
- Check wiring to injectors for an open or short circuit, repair as necessary. Ensure electrical connectors fit tightly and are not corroded. For circuit testing, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
| Application | (1) Ohms | |
|---|---|---|
| Accent | 15.55-16.25 | |
| Elantra | 15.55-16.25 | |
| Santa Fe | ||
| 2.4L | 13.00-16.00 | |
| 2.7L | 13.80-15.20 | |
| 3.5L | 13.00-16.00 | |
| Sonata | 13.00-16.00 | |
| Tiburon | ||
| 2.0L | 15.55-16.25 | |
| 2.7L | 13.00-16.00 | |
| XG350 | 13.00-16.00 | |
| (1) Resistance measured at 68°F (20°C). | ||
| (1) | Resistance measured at 68°F (20°C). |
FUEL INJECTOR RESISTANCE SPECIFICATIONS
Scheme 6
Power Circuit Test (Accent)
Turn ignition off. Disconnect both ignition coils 2-pin harness connectors. Turn ignition on, and measure voltage between ground and both ignition coils harness connectors terminal No. 1. (Scheme 7) Voltage should be battery voltage. If voltage is not as specified, repair open circuit between ignition coil and ignition switch. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
Scheme 7
Power Circuit Test (Elantra & Tiburon 2.0L)
Turn ignition off. Disconnect both ignition coils 2-pin harness connectors. Turn ignition on, and measure voltage between ground and both ignition coils harness connectors terminal No. 2. (Scheme 7) Voltage should be battery voltage. If voltage is not as specified, repair open circuit between ignition coil and engine control relay (relay is located at engine compartment Fuse/Relay box). For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
Power Circuit Test (Santa Fe 2.4L & 3.5L, Sonata 2.4L & XG350)
- Turn ignition off. Disconnect ignition failure sensor 4-pin harness connector, located on upper rear of engine. Turn ignition on, and measure voltage between ground and sensor harness connector terminal No. 4. (Scheme 8) Voltage should be battery voltage. If voltage is as specified, go to next step. If voltage is not as specified, repair open circuit between ignition failure sensor and ignition switch. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
- Turn ignition off. With ignition failure sensor harness connector disconnected, check for continuity between sensor connector terminals No. 3 and 4 (component side). If continuity is present, go to next step. If continuity is not present, replace ignition failure sensor.
- Reconnect ignition failure sensor harness connector. Disconnect all ignition coils 3-pin harness connectors. Turn ignition on, and measure voltage between ground and ignition coils harness connector terminal No. 1. (Scheme 9) Voltage should be battery voltage. If voltage is not as specified, repair open circuit between ignition coils and ignition failure sensor. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
Scheme 8
Scheme 9
Power Circuit Test (Santa Fe 2.7L & Sonata 2.7L)
Turn ignition off. Disconnect ignition coils 4-pin harness connector. Turn ignition on, and measure voltage between ground and harness connector terminal No. 3. (Scheme 10) Voltage should be battery voltage. If voltage is not as specified, repair open circuit between ignition coil and engine compartment Fuse/Relay box. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
Scheme 10
Power Circuit Test (Tiburon 2.7L)
Turn ignition off. Disconnect ignition coils 4-pin harness connector. Turn ignition on, and measure voltage between ground and harness connector terminal No. 3. (Scheme 10) Voltage should be battery voltage. If voltage is not as specified, repair open circuit between ignition coil and BCM box. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
Ground Circuit Test (Accent)
Turn ignition off. Disconnect both 2-pin ignition coils harness connectors. Disconnect 81-pin ECM harness connector. Connect jumper wires between ground and ECM harness connector terminals No. 2 and 5. (Scheme 11) Measure resistance between ground and ignition coil-1 harness connector terminal No. 2 and ignition coil-2 harness connector terminal No. 2. (Scheme 7) Resistance should be one ohm or less. If resistance is not as specified, repair open or short circuit between suspect ignition coil(s) and ECM. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
Scheme 11
Ground Circuit Test (Elantra & Tiburon 2.0L)
Turn ignition off. Disconnect both 2-pin ignition coils harness connectors. Disconnect 81-pin ECM harness connector. Connect jumper wires between ground and ECM harness connector terminals No. 4 and 5. (Scheme 11) Measure resistance between ground and ignition coil-1 harness connector terminal No. 2 and ignition coil-2 harness connector terminal No. 2. (Scheme 7) Resistance should be one ohm or less. If resistance is not as specified, repair open or short circuit between suspect ignition coil(s) and ECM. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
Ground Circuit Test (Santa Fe 2.4L & Sonata 2.4L)
Turn ignition off. Disconnect both ignition coils 3-pin harness connectors. Check resistance between ground and suspect ignition coil harness connector terminal No. 2. (Scheme 9) Resistance should be one ohm or less. If resistance is not as specified, repair open or short circuit between suspect ignition coil and body ground connection G01. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
Ground Circuit Test (Santa Fe 2.7L)
Turn ignition off. Disconnect 4-pin ignition coil harness connector. Disconnect 9-pin ECM harness connector C23-5. Measure ignition coil ground circuits resistance, between ignition coil harness connector terminals and ECM harness connector terminals. (Scheme 10)and (Scheme 12). See IGNITION COIL GROUND CIRCUIT TEST (SANTA FE 2.7L) table. Resistance should be one ohm or less. If resistance is not as specified, repair open or short circuit between ignition coil and ECM. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
| 9-Pin ECM Harness Connector C23-5 | 4-Pin Ignition Coil Harness Connector |
|---|---|
| Terminal No. 1 | Terminal No. 4 |
| Terminal No. 2 | Terminal No. 1 |
| Terminal No. 3 | Terminal No. 2 |
IGNITION COIL GROUND CIRCUIT TEST (SANTA FE 2.7L)
Scheme 12
Ground Circuit Test (Sonata 2.7L)
Turn ignition off. Disconnect 4-pin ignition coils harness connector. Disconnect 9-pin ECM harness connector C94-5. Measure ignition coil ground circuits resistance, between ignition coil harness connector and ECM harness connector C94-5 terminals. (Scheme 10)and (Scheme 13). See IGNITION COIL GROUND CIRCUIT TEST (SONATA 2.7L) table. Resistance should be one ohm or less. If resistance is not as specified, repair open or short circuit between ignition coil and ECM. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
| ECM 9-pin Harness Connector C94-5 | Ignition Coil 4-pin Harness Connector |
|---|---|
| Terminal No. 1 | Terminal No. 4 |
| Terminal No. 2 | Terminal No. 1 |
| Terminal No. 3 | Terminal No. 2 |
IGNITION COIL GROUND CIRCUIT TEST (SONATA 2.7L)
Scheme 13
Ground Circuit Test (Santa Fe 3.5L & XG350)
Turn ignition off. Disconnect 3-pin ignition coils harness connectors. Measure resistance between ground and suspect ignition coil harness connector terminal No. 2. (Scheme 9) Resistance should be one ohm or less. If resistance is not as specified, repair open or short circuit between suspect ignition coil and body ground G11 connection. For circuits identification, see appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
Ignition Coil Resistance Test (Accent, Elantra & Tiburon 2.0L)
Note. Ignition coil-1 is for cylinders No. 1 and 4, and ignition coil-2 is for cylinders No. 2 and 3.
- Turn ignition off. Disconnect both 2-pin ignition coils harness connectors. Measure primary coil resistance between terminals No. 1 and 2 of each ignition coil connector (component side). (Scheme 14) See «DIS IGNITION COIL RESISTANCE»(ref-152016-S34202033632003011300000) table. If resistance is as specified, go to next step. If resistance is not as specified, replace ignition coil.
- Leave ignition coils harness connectors disconnected, and disconnect all spark plug wires (ignition coil side). Measure secondary coil resistance between high-voltage coil towers No. 1 and 4, and between coil towers No. 2 and 3. (Scheme 14) See «DIS IGNITION COIL RESISTANCE»(ref-152016-S34202033632003011300000) table. If resistance is not as specified, replace ignition coil.
| Application | Primary | Secondary | |
|---|---|---|---|
| Accent | 0.78-0.96 Ohm | 11,000-15,000 Ohms | |
| Elantra | 0.45-0.55 Ohm | 10,300-13,900 Ohms | |
| Santa Fe | |||
| 2.4L | 0.78-0.96 Ohm (1) | 10,200-13,900 Ohms | |
| 2.7L | 0.67-0.81 Ohm | 11,300-15,300 Ohms | |
| 3.5L | 0.78 Ohm | 10,400-15,600 Ohms | |
| Sonata | |||
| 2.4L | 0.77-0.99 Ohm (1) | 10,300-13,900 Ohms | |
| 2.7L | 0.67-0.81 Ohm | 11,300-15,300 Ohms | |
| Tiburon | |||
| 2.0L | 0.45-0.55 Ohm | 10,300-13,900 Ohms | |
| 2.7L | 0.67-0.81 Ohm | 11,300-15,300 Ohms | |
| XG350 | 0.67-0.81 Ohm (1) | 10,400-15,600 Ohms | |
| (1) Resistance value is with coil power transistor energized using a 3-volt power supply and ground connected to terminals No. 1 and 2. (Scheme 15) | |||
| (1) | Resistance value is with coil power transistor energized using a 3-volt power supply and ground connected to terminals No. 1 and 2. (Scheme 15) |
DIS IGNITION COIL RESISTANCE - Ohms @ 68°F (20°C)
Scheme 14
Ignition Coil Resistance Test (Santa Fe 2.4L & 3.5L, Sonata 2.4L & XG350)
- Turn ignition off. Disconnect suspect ignition coil 3-pin harness connector. To measure primary ignition coil resistance, connect fused jumper wire between 3-volts power supply ground (-) terminal and ignition coil power transistor terminal No. 2 (component side). (Scheme 15) Connect another fused jumper wire between 3-volts power supply (+) terminal and ignition coil power transistor connector terminal No. 1 (component side). Go to next step
- Measure resistance between ignition coil power transistor terminals No. 2 and 3 (component side). Continuity should be present only when fused jumper wire is connected between 3-volts power supply (+) terminal and ignition coil power transistor connector terminal No. 1 (component side). For resistance specification, see «DIS IGNITION COIL RESISTANCE»(ref-152016-S34202033632003011300000) table. If resistance is as specified, go to next step. If resistance is not as specified, replace ignition coil.
- Disconnect 3-volts power supply and ground from ignition coil power transistor terminals. Also disconnect all spark plug wires (ignition coil side). Measure secondary resistance of each ignition coil between high-voltage coil terminals. (Scheme 15) See «DIS IGNITION COIL RESISTANCE»(ref-152016-S34202033632003011300000) table. If resistance is not as specified, replace ignition coil.
Scheme 15
Ignition Coil Resistance Test (Santa Fe 2.7L & Sonata 2.7L)
- Turn ignition off. Disconnect ignition coil 4-pin harness connector. Measure primary ignition coils resistance, at component side as follows: For cylinders No. 1 and 4, measure resistance between ignition coil connector terminals No. 2 and 4. For cylinders No. 2 and 5, measure resistance between ignition coil connector terminals No. 2 and 3. For cylinders No. 3 and 6, measure resistance between ignition coil connector terminals No. 1 and 2. For illustration of ignition coils resistance test (Scheme 16) For resistance specification, see «DIS IGNITION COIL RESISTANCE»(ref-152016-S34202033632003011300000) table. If resistance is as specified, go to next step. If resistance is not as specified, replace ignition coil.
- Leave ignition coils harness connector disconnected, and disconnect all spark plug wires (ignition coil side). Measure resistance between high-voltage ignition coil towers No. 1 and 4, between coil towers No. 2 and 5, and between coil towers No. 3 and 6. (Scheme 16) For resistance specification, see «DIS IGNITION COIL RESISTANCE»(ref-152016-S34202033632003011300000) table. If resistance is not as specified, replace ignition coil.
