Replacement Procedure

FUEL PUMP SUB-ASSEMBLY REPLACEMENT PROCEDURE:

NOTE:
Verify that the vehicle qualifies for this service campaign by checking the "Warranty Vehicle Information" screen via DCS Interactive or DCS Online.





1. Remove the rear seat cushion of the vehicle.

NOTE:
Elantra 4-door: Pull up to release the spring clips at the front of the cushion.





NOTE:
Tiburon: Push in on the tabs at the front of the cushion to release the clips.





NOTE:
Elantra 5-door: Flip the seat cushion forward and remove the center bolt covering the fuel access door trim clip (passenger side cushion).





NOTE:
Elantra 5-door: Remove the trim clip to flip the cover over the fuel pump access door.





2. Carefully pull/pry open the fuel pump metal access-hole cover.

3. Disconnect the electrical connector at the top of the fuel pump assembly.





NOTE:
The picture shown is of a 2003 MY Elantra Non-SULEV vehicle.





NOTE:
The picture shown is of a SULEV vehicle or a 2004 Elantra.





NOTE:
The picture shown is of a V6 Tiburon.

4. Crank/Start the engine briefly to relieve pressure in the fuel line and fuel pump.

5. Record radio station presets (all 18 stations).





6. Disconnect the battery negative (-) ground side connector.





7. Disconnect the fuel supply line from the fuel pump assembly.

NOTE:
Use a shop rag or equivalent to catch any remaining fuel in the line.

NOTE:
Avoid any potential source of ignition at all times while servicing the fuel system.





8. Remove the mounting screws (8 mm socket).





9. Remove the Rubber Hose for easier pump assembly removal.





10. Remove the fuel pump assembly from the vehicle.

NOTE:
Be sure to use extra care not to bend the fuel level sender float arm when removing the fuel pump module from the fuel tank.

NOTE:
Do not tip the removed fuel pump module assembly inside the vehicle. The fuel contained in the reservoir may spill.





11. Separate the "cap" assembly from the reservoir assembly by pressing in the three tabs.

The housing springs may separate from the cap. Keep the springs and cap for use later.





NOTE:
This picture shows the 2.0L fuel pump module separated into the three main parts for reference.





12. Disconnect the fuel pump connector. Also, disconnect the sending unit connector at the cap assembly.





NOTE:
This picture shows the 2.7L fuel pump module separated into the three main parts for reference.





13. Separate the "reservoir" from the pump/filter sub-assembly by prying with a small screw driver (or equivalent) between the reservoir and filter/pump assembly at the 3 indicated mounting points.





NOTE:
Rinse the reservoir if any debris exists. Save the reservoir.





14. Install the new filter/pump sub-assembly into the reservoir, making sure it locks at all three tabs.

15. Connect the fuel pump connector.

16. Install the "cap" assembly to the reservoir to complete the fuel pump module reassembly.

17. Reassemble as follows:

a. Reinstall the fuel pump assembly to the fuel tank. (Mounting bolt torque specification = 18-26 lb-inch)

b. Reconnect the fuel lines.

c. Reconnect the fuel pump connector.

d. Reinstall the rear seat. (Mounting bolt torque specification = 12-19 lb-ft)

e. Reconnect the battery and verify repair by starting the engine.

f. Reset all 18 preset radio stations and set the clock to the correct time.