Wednesday, August 13, 2014

How To Replace Hyundai Sonata Fuel Pump Replacement 2004 - 2010

2004-2010 Hyundai Sonata Fuel Pump Replacement

This blog is not responsible for any damages or injuries caused by following these steps

Tools needed:
- Hammer
- couple flat head screw drivers
- phillips screw driver

Deprime the fuel line and disconnect the battery for safety. 


I recommend using Delphi fuel pump with lifetime warranty from Autozone. I have never had to replace another one since using them. 

 First open the trunk and pull the carpet cover off.

You will see the cover for the fuel tank in the very back of the trunk.

It can also be accessed from inside the car behind the rear passenger side seat. 

Remove the 4 philips screws holding the cover plate over the fuel pump.

Once the plate is removed you will see the top of the tank and the fuel pump does not line up directly to the hole but it will fit through.

You will need to unplug the 2 plugs to get the plate out of the way. 

Next you will need to remove the 2 fuel lines 
the one with the green clip push in on the front part of the clip and it will slid off. 

The orange clip you must first slide the orange clip back.
Next push in on the yellow tabs on both sides and pull up. 

once the hoses and plugs have been removed, clean the area around to keep from contaminants falling into the tank. 
Then use a screwdriver and a hammer to tap off the ring around the fuel pump. 
It is recommended to use a brass hammer and chisel for this to prevent sparks. 
The ring will turn counter clockwise to screw off, by pounding on these areas.

If rusted out to badly you can purchase a new one at Autozone

Once the ring is off you can begin pulling the fuel pump out 
by turning and twisting it will eventually come out.
Be careful not to mess up the fuel level sensor. 
Also be careful not to lose the o ring down in the tank as well, 
and when reinstalling make sure the
 o ring is seated properly at the top of the tank. 

With the pump out now you must pull the pump assembly apart to replace the pump itself. 

First, unplug the 2 plugs on the bottom side of the top of the pump assembly.

Next, remove the clip holding this part onto the assembly.

Now go around with a screwdriver and pop off the outer shell of the fuel pump assembly.

I used a flat head Craftsmen screw driver to pry out and up to pop the 3 taps out.

You will then end up with 2 separate parts. 

Now the very bottom of the inside part has 4 clips that also must be popped out in order to get the fuel pump out. 

Again use a flathead screwdriver in order to remove the cap.

Once removed the fuel pump will come right out.

The last thing you will need to pull the strainer off the bottom of the pump.
it is removed by simply pulling it down and it will slid off. 
It is recommended to replace this strainer as well. It also can be found at your local Autozone store.  

Repeat all these steps in reverse to put it all back together.