Fuel Delivery System Hyundai Santa Fe III

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1. Release the residual pressure in fuel line. (Refer to Fuel Delivery System - " «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system__release-residual-pressure-in-fuel-line) ") CAUTION: 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.
2. Install the Special Service Tool (SST). Disconnect the fuel feed tube from the high pressure fuel pump. CAUTION: There may be some residual pressure even after "Release Residual Pressure in Fuel Line" work, so cover the hose connection with a shop towel to prevent residual fuel from spilling out before disconnecting any fuel connection. Install the special service tool for measuring the fuel pressure in between the fuel feed tube and the high pressure fuel pump (Refer to the (Scheme 4) below).
3. Inspect fuel leakage on connections among the fuel feed tube, the high pressure fuel pump, and the SST components with IG ON.
4. Measure Fuel Pressure. Start the engine and measure the fuel pressure at idle. Fuel Pressure: 480 ~ 520 kPa (4.9 ~ 5.3 kgf/cm 2, 69.6 ~ 75.4 psi) NOTE: If the fuel pressure differs from the standard value, repair or replace the related part (Refer to the table below). Fuel Pressure Cause Related Part Too Low Fuel filter clogged Fuel Filter Fuel leakage Fuel Pressure Regulator Too High Fuel pressure regulator stuck Fuel Pressure Regulator Stop the engine, and then check for the change in the fuel pressure gauge reading. Standard Value: The gauge reading should hold for about 5 minutes after the engine stops NOTE: If the gauge reading should not be held, repair or replace the related part (Refer to the table below). Fuel Pressure (After Engine Stops) Cause Related Part Fuel Pressure Drops Slowly Leakage on injector Injector Fuel Pressure Drops Immediately Check valve of fuel pump stuck open Fuel Pump Turn the ignition switch OFF.
5. Release the residual pressure in fuel line. (Refer to Fuel Delivery System - " «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system__release-residual-pressure-in-fuel-line) ") CAUTION: 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.
6. Test End Remove the Special Service Tool (SST) from the fuel feed tube and the high pressure fuel pump. Connect the fuel feed tube and the high pressure fuel pump.

Release Residual Pressure in Fuel Line

Note. Wear safety glasses and fuel resistant gloves.

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1. Turn the ignition off and disconnect the battery negative cable.
2. Remove the fuel pump fuse (A).
3. Disconnect the electrical connector from the high pressure fuel pump.
4. Reconnect the battery negative cable.
5. Run the engine for about 20 seconds to lower the pressure in both the high or low pressure lines. The engine may shut off within the 20 second period. If not, turn the engine off.
6. Proceed with the service or repair. Use rags to cover opening and catch spills when opening up the high pressure system.
7. Reinstall/re-connect all components in reverse order of removal. Start engine and confirm proper operation, and make sure there are no fuel leaks.
8. After completing, clear DTC(s) using GDS scan tool (the procedure described above will cause DTC to set).

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1. Release the residual pressure in fuel line. (Refer to Fuel Delivery System - " «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system__release-residual-pressure-in-fuel-line) ")
2. Remove the rear seat assembly. (Refer to " «REAR SEAT ASSEMBLY»(/hyundai/santa-fe/iii-2012-2016/remont/seats/#rear-seat) ")
3. Remove the fuel pump service cover (A).
4. Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B).
5. Disconnect the fuel feed tube quick connector (C).
6. Remove the rear - LH wheel & tire.
7. Lift the vehicle and support the fuel tank with a jack.
8. Remove the center & rear muffler assembly. [4 WD] (Refer to " «MUFFLER»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) ")
9. Remove the propeller shaft. [4WD] (Refer to " «PROPELLER SHAFT»(/hyundai/santa-fe/iii-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft-assembly) ")
10. Disconnect the fuel filler hose (A) and the ventilation tube quick-connector (B).
11. Disconnect the ventilation tube quick-connector (A).
12. Disconnect the vapor tube quick-connector (B).
13. Remove the fuel tank (B) from the vehicle after removing the fuel tank band (A). NOTE: When removing the fuel tank, the fuel tank must be tilted because of interfering with coupling.

Installation

1. Install in the reverse order of removal. Fuel tank band installation bolt: 44.1 ~ 58.8 N.m (4.5 ~ 6.0 kgf.m, 32.6 ~ 43.4 lb-ft)

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1. Turn the ignition switch OFF, and then remove battery (-) cable.
2. Remove the fuel pump assembly.
3. Check motor operation by fuel pump connector (A) connecting power (No. 4) and ground (No. 5). Pin No. Description 1 - 2 Fuel sender signal 3 Fuel sender ground 4 Fuel pump motor (+) 5 Fuel pump motor ground

Scheme 12

1. Turn the ignition switch OFF, and then remove battery (-) cable.
2. Remove the fuel pump assembly.
3. Using an ohmmeter, measure the resistance between terminals 2 and 3 of sender connector (A) at each float level. Pin No. Description 1 - 2 Fuel sender signal 3 Fuel sender ground 4 Fuel pump motor (+) 5 Fuel pump motor ground
4. Also check that the resistance changes smoothly when the float is moved from "E" to "F". Position Resistance(ohms) E 197 ~ 203 Warning lamp 168 ~ 172 1/2 64.2 ~ 68.2 Sender (F) 6 ~ 10

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1. Release the residual pressure in fuel line. (Refer to Fuel Delivery System - " «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system__release-residual-pressure-in-fuel-line) ")
2. Remove the rear seat. (Refer to " «REAR SEAT ASSEMBLY»(/hyundai/santa-fe/iii-2012-2016/remont/seats/#rear-seat) ")
3. Remove the fuel pump service cover (A).
4. Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B).
5. Disconnect the fuel feed tube quick connector (C).
6. Remove locking ring (A) by using the special service tool. Information The locking ring should be removed by a locking ring remover as below. This tool can be purchased from a common tool supplier.

1. Install in the reverse order of removal. CAUTION: Be careful of fuel pump direction when installing (Refer to the groove in the «FUEL TANK»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system) ).

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1. Remove the fuel pump. (Refer to Fuel Delivery System - " «FUEL PUMP»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system) ")
2. Disconnect the electric pump wiring connector (A) and the fuel sender connector (B).
3. Remove the fuel sender (A) after releasing the fix hook.
4. Remove the fixing clip, and then disconnect the fuel feed tube quick-connector (B).
5. Remove the head assembly (C) after releasing the fixing hooks.
6. Remove the reservoir-cup (A) after releasing the fixing hooks.
7. Remove the cap (A), and then remove the assist pump (B).
8. Disconnect the ground cable (A).
9. Remove the fuel pressure regulator (B) after releasing the fixing hooks.
10. Disconnect the ground cable connector (A) and the fuel pump tube cap (B).
11. Separate the electric pump motor from the fuel filter after releasing the fixing hooks (A).

1. Install in the reverse order of removal.

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1. Remove the fuel pump. (Refer to Fuel Delivery System - " «FUEL PUMP»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system) ")
2. Disconnect the electric pump wiring connector (A) and the fuel sender connector (B).
3. Remove the fuel sender (A) after releasing the fix hook.
4. Remove the fixing clip, and then disconnect the fuel feed tube quick-connector (B).
5. Remove the head assembly (C) after releasing the fixing hooks.
6. Remove the reservior-cup (A) after releasing the fixing hooks.
7. Remove the cap (A), and then remove the assist pump (B).
8. Disconnect the ground cable (A).
9. Remove the fuel pressure regulator (B) after releasing the fixing hooks.
10. Disconnect the ground cable connector (A) and the fuel pump tube cap (B).
11. Separate the electric pump motor from the fuel filter after releasing the fixing hooks (A).

1. Install in the reverse order of removal.

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1. Remove the fuel pump. (Refer to Fuel Delivery System - " «FUEL PUMP»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system) ")
2. Disconnect the electric pump wiring connector (A) and the fuel sender connector (B).
3. Remove the fuel sender (A) after releasing the fix hook.

1. Install in the reverse order of removal.

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1. Remove the fuel pump. (Refer to Fuel Delivery System - " «FUEL PUMP»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system) ")
2. Disconnect the electric pump wiring connector (A) and the fuel sender connector (B).
3. Remove the fuel sender (A) after releasing the fix hook.
4. Remove the fixing clip, and then disconnect the fuel feed tube quick-connector (B).
5. Remove the head assembly (C) after releasing the fixing hooks.
6. Remove the reservior-cup (A) after releasing the fixing hooks.
7. Remove the fuel pressure regulator (A) after releasing the fixing hooks.

1. Install in the reverse order of removal.

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1. Turn the ignition switch OFF, and then remove battery (-) cable.
2. Release the residual pressure in fuel line. (Refer to Fuel Delivery System - " «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system__release-residual-pressure-in-fuel-line) ")
3. Disconnect the low pressure fuel quick-connector (A).
4. Disconnect the vapor hose (A) which is connected from the PCSV.
5. Lift the vehicle.
6. Remove the fuel tank. (Refer to Fuel Delivery System - " «FUEL TANK»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system) ")
7. Disconnect the vapor tube quick-connector (A).
8. Open the vapor tube and low fuel line fixing clip to using driver.
9. Release the under cover (A) after remove the mounting bolts.
10. Disconnect the fuel & brake line protect (A) from the fixing clip.
11. Disconnect the fuel line fixing bracket (A) to engine room low.
12. Remove the fuel line.

1. Install in the reverse order of removal.

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1. Lift the vehicle.
2. Disconnect the fuel filler hose (A).
3. Disconnect the ventilation tube quick-connector (B).
4. Open the fuel filler door and unfasten the filler-neck assembly mounting screw (A).
5. Remove the rear-LH wheel, tire and the inner wheel house.
6. Remove the filler-neck assembly from the vehicle after removing the bracket mounting nut (A).

1. Install in the reverse order of removal. Filler-neck assembly bracket installation nut: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

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1. Turn the ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the accelerator position sensor connector (A).
3. Remove the installation nuts (C), the bolt (B) and then remove the accelerator pedal module.

1. Install in the reverse order of removal. Accelerator pedal module installation nut: 16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft) Accelerator pedal module installation bolt: 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

Removal

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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»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system__release-residual-pressure-in-fuel-line) ") CAUTION: 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.
3. Disconnect the injectors & rail pressure sensor connector (A).
4. Remove the intake manifold. (Refer to " «INTAKE MANIFOLD»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) ")
5. Remove the injector foam (A).
6. Remove the high pressure fuel pipe. Loosen the flange nut in the order of A, B with SST(09314-3V100). Remove the high pressure pipe bracket bolt (A). Remove the function block installation bolt (A).
7. Remove the installation bolt (A), and then remove the delivery pipe and injector assembly from the engine.

1. Installation is reverse of removal. Delivery pipe installation bolt: 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft) High pressure fuel pipe installation nut: 29.4 ~ 35.3 N.m (3.0 ~ 3.6 kgf.m, 21.7 ~ 26.0 lb-ft) High pressure fuel pipe function block installation bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft) High pressure fuel pipe bracket installation bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

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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»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system__release-residual-pressure-in-fuel-line) ") CAUTION: 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.
3. Remove the pump foam (A).
4. Disconnect the fuel pressure control valve connector (A) and the fuel feed tube quick-connector (B).
5. Remove the intake manifold. (Refer to " «INTAKE MANIFOLD»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) ")
6. Remove the injector foam (A).
7. Remove the high pressure fuel pipe. Remove the high pressure pipe flange nut in order of A, B with the special service tool [SST No.: 09314-3V100] Remove the high pressure pipe bracket bolt (A). Remove the function block installation bolt (A).
8. Remove the installation bolts (A), and then remove the high pressure fuel pump (B) from the cylinder head assembly. CAUTION: Unscrew in turn the two bolts in small step (0.5 turns). In case of fully unscrewing one of the two bolts with the other bolt installed, the housing surface of the cylinder head may be broken because of tension of the pump spring.

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1. Installation is reverse of removal. NOTE: Use the special service tool [SST No.: 09314-3V100] to install the high pressure fuel pipe. High pressure fuel pump installation bolt: 12.8 ~ 14.7 N.m (1.3 ~ 1.5 kgf.m, 9.4 ~ 10.9 lb-ft) High pressure fuel pipe installation nut: 29.4 ~ 35.3 N.m (3.0 ~ 3.6 kgf.m, 21.7 ~ 26.0 lb-ft) High pressure fuel pipe function block installation bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft) High pressure fuel pipe bracket installation bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

See also:
• REAR SEAT ASSEMBLY
• MUFFLER
• PROPELLER SHAFT
• RELEASE RESIDUAL PRESSURE IN FUEL LINE
• FUEL TANK