Hyundai 31111-1G500 Pump-Fuel

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General checks include ensuring there is enough fuel in the tank and verifying that the fuel pump is running by listening for a whirring noise when the ignition is turned on. If there is no sound, the EFI fuse and circuit opening or fuel pump relay should be checked. If voltage is present at the fuel pump electrical connector, the fuel pump is defective, but if no voltage is present, the PCM may be defective. To test fuel pressure, a fuel pressure gauge and T-fitting are needed. For return-type fuel systems, the fuel pump should run for two seconds when the ignition is turned on, and the pressure should hold steady. If the pressure is high, the vacuum hose should be checked for adequate vacuum, and if there is an adequate vacuum but high pressure, a restricted fuel return hose or line should be checked. If the pressure is low, pinching the fuel return hose can determine if the pressure increases, and if not, the fuel filter and supply hose should be checked for restrictions. The fuel pressure regulator can also be checked by disconnecting the vacuum hose and observing the fuel pressure gauge. If the pressure drops substantially after five minutes, there may be a leaking injector or faulty check valve in the fuel pump. For returnless fuel systems, if the fuel pressure is low, the fuel supply hose and line should be inspected for obstructions, and if the pressure is high, the fuel pump/fuel pressure regulator should be replaced. After testing, the fuel pressure should be relieved, the fuel pressure gauge removed, and the engine started to check for fuel leaks.

Install new bolts and tighten them.

Some models have an anti-theft radio; ensure you have the activation code before disconnecting the battery.

Make sure the camshaft lobe is at its base circle and lubricate the pump roller with engine oil. Align the tab on the roller body with the groove in the bore of the valve cover and install the roller. Lubricate the pump O-ring and set the pump onto the valve cover, then tighten the bolts alternately and evenly until the pump is seated.

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.

First, relieve the system fuel pressure and disconnect the negative battery cable. Then, depending on the model year, either reconnect the fuel pump connector or reinstall the fuel pump fuse. For older models, locate the fuel filter and remove the cable tie that attaches the fuel pressure line to the fuel return line. Unplug the brake fluid level sensor electrical connector from the master cylinder. Put a shop rag around the fuel line retaining bolt on top of the fuel filter and remove the bolt to disconnect the fuel line. Connect a fuel pressure gauge to the fuel filter (or fuel rail for newer models) in place of the fuel line. Reconnect the negative battery cable, start the engine, and check for leaks. Measure the fuel pressure and compare it to the specified measurement. Finally, disconnect the vacuum line from the fuel pressure regulator - the fuel pressure should immediately increase. Measure the fuel pressure again and compare it to the specified measurement.

Yes, the fuel level sending unit can be replaced on 1999 through 2005 models. It can be unclipped from the main assembly.