Hyundai Santa Fe (TM): Fuel Delivery System - Engine Control/Fuel SystemHyundai Santa Fe (TM): Fuel Delivery System

Components and components location

Components Location

1. Fuel tank
2. Fuel pump
3. Fuel filter
4. Fuel pump motor
5. Fuel level sender (FLS)
6. Fuel pressure regulator
7. Fuel tank air filter

8. Fuel tank band
9. Fuel filler hose
10. Leveling hose
11. Vent hose
12. Vapor tube
13. Canister

Fuel pressure test

Fuel Pressure Test
1.
Release the residual pressure in fuel line.
(Refer to Delivery System - "Release Residual Pressure in Fuel Line")
  
When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.
2.
Install the Special Service Tool (SST).
(1)
Disconnect the fuel feed tube from the delivery pipe.
  
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.
(2)
Install the special service tool for measuring the fuel pressure in between the fuel feed tube and the fuel delivery pipe. (Refer to the figure below)

3.
Inspect fuel leakage on connections among the fuel feed tube, the delivery pipe, and the SST components with IG ON.
4.
Measure Fuel Pressure.
(1)
Start the engine and measure the fuel pressure at idle.
Fuel Pressure :
330 - 370 kPa (3.4 - 3.8 kg/cm², 47.9 - 53.7 psi)
  
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 valve stuck
Fuel Pressure Regulator

(2)
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
  
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

(3)
Turn the ignition switch OFF.
5.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
  
When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.
6.
Test End
(1)
Remove the Special Service Tool (SST) from the fuel feed tube and the delivery pipe.
(2)
Connect the fuel feed tube and the delivery pipe.

Release residual pressure in fuel line

Release Residual Pressure in Fuel Line
  
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.
1.
Turn the ignition switch OFF and disconnect the battery (-) cable.
2.
Remove the fuel pump fuse (A).

3.
Connect the battery (-) cable.
4.
Start the engine and let idle, and then turn the ignition switch OFF after the engine has stopped on its own.
5.
Disconnect the battery (-) cable, and then install the fuel pump fuse.
6.
Connect the battery (-) cable.
7.
Delete the Diagnostic Trouble Code (DTC) related the fuel pump fuse with the diagnostic tool.
  
When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the diagnostic tool after completion of "Release Residual Pressure in Fuel Line" work.

Fuel Tank. Repair procedures

Removal
  
Be careful not to damage the parts located under the vehicle (floor under cover, canister, fuel tank) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
1.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
2.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
3.
Remove the rear seat (LH).
(Refer to Body - "Rear Seat Assembly")
4.
Remove the rear duct (A).

5.
Remove the fuel pump service cover (A).

  
When removing the fuel pump service cover, remove the 4 clips by rotating them clockwise as shown in the below illustration.

6.
Disconnect the fuel pump connector (A).
7.
Disconnect the fuel feed tube quick connector (B).

8.
Lift the vehicle.
9.
Remove the propeller shaft assembly [4WD].
(Refer to Driveshaft and Axle - "Propeller shaft Assembly")
10.
Remove the center muffler assembly.
(Reter to Engine Mechanical System - "center muffler")
11.
Remove the floor under cover (A).
Tightening torque :
7.9 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

12.
Disconnect the ventilation hose quick-connector (A).
13.
Disconnect the vapor hose quick-connector (B).

14.
Separate the fuel filler hose (A).
Tightening Torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)
15.
Disconnect the ventilation hose quick-connector (B)
16.
Disconnect the leveling hose quick-connector (C).

17.
Support the fuel tank with a jack (A).

  
Insert the rubber block between the fuel tank and jack to prevent damage to the fuel tank.
18.
Remove the fuel tank band (A) and then remove the fuel tank (B).
Fuel tank band mounting bolt (front) : 44.1 - 58.8 N·m (4.5 - 6.0 kgf·m, 32.5 - 43.4 lb·ft)
Fuel tank band mounting nut (rear) : 39.2 - 53.9 N·m (4.0 - 5.5 kgf·m, 28.9 - 39.8 lb·ft)

Installation
1.
Install in the reverse order of removal.

Fuel Pump. Repair procedures

Inspection
[Fuel Pump]
1.
Turn ignition switch OFF and disconnect the negative (-)battery cable.
2.
Remove the fuel pump assembly.
3.
Check motor operation by fuel pump connector (A) connecting power (No.2) and ground (No.4)

Pin No
Discription
1
Fuel sender signal
2
-
3
Fuel sender ground
4
Fuel pump (+)
5
Fuel pump (-)

[Fuel Sender]
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Remove the fuel pump assembly.
3.
Using an ohmmeter, measure the resistance between terminals 1 and 3 of sender connector (A) at each float level.

Pin No
Discription
1
Fuel sender signal
2
-
3
Fuel sender ground
4
Fuel pump (+)
5
Fuel pump (-)

4.
Also check that the resistance changes smoothly when the float is moved from "E" to "F".
Position
Resistance (Ω)
Capacity (ℓ)
E
297 - 305
3
1/2
85.5 - 87.5
32.7
F
14 - 16
65

Removal
1.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
2.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
3.
Remove the rear seat (LH).
(Refer to Body - "Rear Seat Assembly")
4.
Remove the rear duct (A).

5.
Remove the fuel pump service cover (A).

  
When removing the fuel pump service cover, remove the 4 clips by rotating them clockwise as shown in the below illustration.

6.
Disconnect the fuel pump connector (A).
7.
Disconnect the fuel feed tube quick connector (B).

8.
Remove the locking ring (A) by using the special service tool [No.: 09310-B8100].
  
When removing the plate cover, be careful not to damage the fuel tank and fuel pump.
When removing the plate cover, press the upper area with hand and rotate the wrench counter clockwise.

Installation
1.
Install in the reverse order of removal.

Fuel Filter. Repair procedures

Removal
1.
Remove the fuel pump.
(Refer to Fuel System - "Fuel Pump")
2.
Disconnect the fuel sender connector (A).

3.
Release the fixing hook (A) and then remove fuel sender (B) in the arrow direction.

4.
Remove the fixing pin (A) and then disconnect the fuel feed tube (B).

5.
Disconnect the fuel pump motor connector (A).

6.
Release the fixing hook (A) and then remove the head assembly (B).

7.
Release the fixing hook (A) and then remove the reservoir-cup (B).

8.
Disconnect the fuel pump motor connector (A).
9.
Disconnect the ground cable (B).

10.
Remove the fixing pin (A) and then disconnect the fuel pressure regulator (B).

11.
Release the fixing hook and then remove the assist pump (A).

12.
Separate the fuel pump hose (A) after releasing the clamp (B).

  
Replace the clamp with a new one when reinstalling the clamp.
13.
Remove the pump filter & fuel pump (A) after releasing the hooks.

14.
Release the fixing hook and then remove the fuel filter (A) from the bracket (B).

Installtion
1.
Install in the reverse order of removal.

Fuel Pump Motor. Repair procedures

Removal
1.
Remove the fuel pump.
(Refer to Fuel System - "Fuel Pump")
2.
Disconnect the fuel sender connector (A).

3.
Release the fixing hook (A) and then remove fuel sender (B) in the arrow direction.

4.
Remove the fixing pin (A) and then disconnect the fuel feed tube (B).

5.
Disconnect the fuel pump motor connector (A).

6.
Release the fixing hook (A) and then remove the head assembly (B).

7.
Release the fixing hook (A) and then remove the reservoir-cup (B).

8.
Disconnect the fuel pump motor connector (A).
9.
Disconnect the ground cable (B).

10.
Remove the fixing pin (A) and then disconnect the fuel pressure regulator (B).

11.
Release the fixing hook and then remove the assist pump (A).

12.
Separate the fuel pump hose (A) after releasing the clamp (B).

  
Replace the clamp with a new one when reinstalling the clamp.
13.
Remove the pump filter & fuel pump (A) after releasing the hooks.

Installtion
1.
Install in the reverse order of removal.

Fuel Sender. Repair procedures

Removal
1.
Remove the fuel pump.
(Refer to Fuel System - "Fuel Pump")
2.
Disconnect the fuel sender connector (A).

3.
Release the fixing hook (A) and then remove fuel sender (B) in the arrow direction.

Installation
1.
Install in the reverse order of removal.

Fuel Pressure Regulator. Repair procedures

Removal
1.
Remove the fuel pump.
(Refer to Fuel System - "Fuel Pump")
2.
Disconnect the fuel sender connector (A).

3.
Release the fixing hook (A) and then remove fuel sender (B) in the arrow direction.

4.
Remove the fixing pin (A) and then disconnect the fuel feed tube (B).

5.
Disconnect the fuel pump motor connector (A).

6.
Release the fixing hook (A) and then remove the head assembly (B).

7.
Release the fixing hook (A) and then remove the reservoir-cup (B).

8.
Disconnect the fuel pump motor connector (A).
9.
Disconnect the ground cable (B).

10.
Remove the fixing pin (A) and then disconnect the fuel pressure regulator (B).

Installation
1.
Install in the reverse order of removal.

Fuel Line. Repair procedures

Removal
  
Be careful not to damage the parts located under the vehicle (floor under cover, canister, fuel tank) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
1.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
2.
Turn the ignition switch OFF and disconnect the negative (-) battery terminal.
3.
Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
4.
Remove the battery and battery tray.
(Refer to Engine Electrical System - " Battery")
5.
Disconnect the fuel delivery line quick-connector (A).

  
When removing the quick-connnector with the clip removing tool (A), be careful not to damage the plastic clip (B).
If the clip is damaged, it can cause a fuel leak due to bad connection and could result in a fire.

6.
Disconnect the vapor hose (A) which is connected from the purge control solenoid valve.

7.
Separate the vapor tube and fuel feed tube line fixing clips (A).

8.
Lift the vehicle.
9.
Remove the floor under cover (A).
Tightening torque :
7.9 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

10.
Disconnect the vapor hose quick-connector (A) from the canister.

11.
Remove the fuel tank.
(Refer to Fuel Delivery System - "Fuel Tank")
12.
Loosen the fuel line protector mounting bolt and nut (A).
Tightening torque :
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.6 lb-ft)

13.
Release the fixing clip (A) of the vapor and fuel feed tube line using a driver.
14.
Remove the fuel line from the bottom of the vehicle.

Installation
1.
Install in the reverse order of removal.

Filler-Neck Assembly. Repair procedures

Removal
1.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
2.
Lift the vehicle.
3.
Remove the rear-left wheel & tire and wheel house cover.
4.
Open the fuel filler cap (A) by turning it in the counterclockwise.

5.
Separate the fuel filler hose (A).
6.
Disconnect the ventilation hose quick-connector (B)
7.
Disconnect the leveling hose quick-connector (C).

8.
Remove the filler-neck assembly (A) after loosening the mounting nut (B).
Tightening Torque :
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb.ft)

Installation
1.
Install in the reverse order of removal.

Accelerator Pedal. Repair procedures

Removal
1.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
2.
Disconnect the accelerator position snesor connector (A).

3.
Disconnect the mounting cap (A).

4.
Remove the accelerator pedal module from the vehicle after loosening the mounting bolt (A).
Tightening Torque :
8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb.ft)

Installation
1.
Install in the reverse order of removal.

Delivery Pipe. Repair procedures

Removal
1.
Release the residual pressure in fuel line.
Release the residual pressure in fuel line.
2.
Turn the ignition switch OFF and disconnect the battery (-) terminal.
3.
Disconnect the fuel delivery line quick-connector (A).

  
Open the clamp cover (B) before disconnecting the quick-connector. (If the clip is applied)

  
When removing the quick-connnector with the clip removing tool (A), be careful not to damage the plastic clip (B).
If the clip is damaged, it can cause a fuel leak due to bad connection and could result in a fire.

4.
Disconnect the injector connector (A).

5.
Remove the delivery pipe & injector assembly after loosening the bolt (A).
Tightening Torque
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

Installation
1.
Install in the reverse order of removal.
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