Hyundai 94460-0A500 Fuel Pump Sender Assembly

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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.

Once you have removed the fuel pump/fuel level sensor from the fuel tank, you can replace the entire assembly, or you can disassemble it and replace the fuel inlet strainer, the fuel pump or the fuel level sensor. Remove the fuel pump/fuel level sensor assembly from the fuel tank. Drain any residual gasoline from the fuel pump/fuel level sensor, then place the fuel pump/fuel level sensor on a clean workbench. Make sure that the work area is well ventilated, because there will be gasoline evaporating from the pump/sensor for a while. Check the filter for clogging. If in doubt, replace it. The fuel level sensor can be replaced on 1999 through 2005 models. Unclip it from the main assembly. Other components such as the pressure regulator and the pump may be serviceable with individual aftermarket parts available from a local parts store. Reassembly is the reverse of disassembly. Install the fuel pump/fuel level sensor in the fuel tank. For 2011 and later models, depress the fuel pump/sensor locking tabs at the top and remove the top of the assembly. Disconnect the fuel feed line quick-disconnect connector. Remove the mounting clip and disconnect the fuel line. Depress the reservoir cup locking tabs and remove the reservoir cup (outer housing). Disconnect the ground cable, then remove the assist pump and the fuel pressure regulator. Depress the fuel filter locking tabs and separate the fuel filter from the fuel pump. Remove the fuel filter. Installation is the reverse of removal.