Replacing Fuel Level Sensor In 2008 Santa Fe: Step-By-Step Guide

Replacing the fuel level sensor in a 2008 Santa Fe is a moderately challenging task. The rear seats must be removed to access the fuel tank, and a specialised tool is required to remove the fuel tank cover. The fuel lines must be disconnected, and the fuel pump fuse or relay removed to depressurise the system. The fuel pump sender assembly can then be removed, and the fuel level sensor replaced.

Removing the rear seats

To remove the rear seats of your 2008 Santa Fe, you will need to remove the bolts holding the seats in place. There are four bolts per seat, two in the front and two in the back. To access the front bolts, you will need to pop off the plastic covers. With the covers removed, tilt the seat back forward until you have enough room to fit a socket wrench through the gap to remove the bolts.

Once the bolts are removed, the rear seats can be lifted out of the vehicle. This will provide access to the fuel pump service cover, which is located under the carpet in the cargo area.

Disconnecting the fuel lines

Preparation

Before beginning, ensure you have the necessary tools, including a fuel sender lock tool (OTC 6599 or equivalent), a rubber mallet, and a breaker bar. It is also recommended to have a second pair of hands to assist with the process. Allow the car to sit overnight if possible, to ensure the system is depressurised.

Depowering the Fuel System

To avoid fuel spray, it is essential to relieve the pressure in the fuel system. Remove the pump fuse or relay, then run the car until it stalls. This will ensure most of the pressure is released.

Accessing the Fuel Tank

Remove the rear 60/40 seat to access the fuel tank. You may need to cut the carpet and padding to fully expose the tank. Remove the fuel pump/fuel level sensor floor service hole cover and disconnect the wiring.

• Disconnect the fuel lines from the fuel pump. There are two fuel lines connected to the pump, and both need to be removed. The first is a quick-release connector with a "button" that needs to be pressed to release. The second has a locking clip that must be pushed down to disconnect.
• Absorb any residual fuel with rags to minimise mess and fire risk.
• Remove the crossover tube that connects the two sending units in the tank. This will provide additional clearance when removing the fuel pump assembly.

Removing the Fuel Pump Assembly

• Using the fuel sender lock tool and a breaker bar, loosen and remove the lock ring that holds the fuel pump assembly in place. Significant force may be required, especially if the ring is rusted.
• Carefully lift the fuel pump assembly out of the tank. It is spring-loaded, so expect it to pop up slightly when the ring is removed. Take care not to damage the assembly or any surrounding components.
• With the assembly partially out of the tank, disconnect the wiring harness. Gently pull the harness through the service hole, ensuring you do not kink or damage the wires.

At this point, you have successfully disconnected the fuel lines from the fuel pump assembly and can proceed with replacing the fuel level sensor. Remember to work carefully and patiently throughout the process, as dealing with fuel systems can be hazardous if not done correctly. Always put safety first.

Removing the fuel pump/fuel level sensor assembly

To remove the fuel pump/fuel level sensor assembly, you will need to remove the rear seat, cut the carpet and padding below it to access the fuel tank.

Removing the rear seat

Remove the 8 bolts (4 per seat) holding the rear seat in place. The 4 bolts in front are covered by plastic, which you will need to pop off to expose the bolt. Tilt the seat back forward until you have enough room to get a socket through the gap.

Accessing the fuel tank

Remove the carpet patches to expose the fuel pump service cover. There are bolt location marks under the carpet patches.

Removing the fuel pump service cover

Gently pry up the fuel pump service cover with a screwdriver or pry bar. Go around slowly, trying not to warp the cover. The cover is held on by black silicone glue.

Disconnecting the wiring harness

Release the wiring harness connector under the service cover. Push the rubber grommet out of the service cover and remove the wire.

Depressurising the fuel system

Before removing any fuel lines, depressurise the fuel system. Pull the pump fuse or relay and run the car until it stalls. This will relieve most of the fuel pressure from the system.

Removing fuel lines

Prepare some rags to soak up any residual gas in the lines. Press down on the "button" (quick release) in the square from the image below and pull the fuel line out.

Removing the lock ring

Attach your breaker bar and turn counter-clockwise. You will need to apply significant force to loosen the ring. A special tool, the OTC 6599 Universal Fuel Sender Lock Tool, is available for this purpose, but a hammer and flathead screwdriver or chisel can also be used.

Removing the second fuel line

Remove the second fuel line by pushing down on the clip and turning counter-clockwise.

Removing the fuel pump

Carefully lift the fuel pump out about halfway. You may need to turn/angle it to get it out. Be gentle, and pay attention to how the wire is wrapped around the pump so you can do the same with the new sensor. The pump is spring-loaded, so expect it to pop up a little.

Removing the fuel level sensor

The sensor slides in and out and is held in place by a notch. It will click in and out.

Installing the new fuel level sensor

Slide the new sensor into place. Reinstall the fuel lines, making sure to clip them into place. Reinstall the lock ring, ensuring that you hear a loud click signalling that the cover is fully locked and the tank can be pressurised.

Reinstalling the fuel pump

Clean up any debris in the area with a vacuum. Reinstall the fuel pump, ensuring that the wire is wrapped correctly. Push the pump back into the tank and reconnect the wiring harness.

Reinstalling the fuel pump service cover

Apply some black silicone to the service cover and put some books or any weighted object on the cover while the silicone sets.

Tips

• It is highly recommended to get the OTC 6599 Universal Fuel Sender Lock Tool for removing the lock ring. While it is possible to use a hammer and flathead screwdriver or chisel, this carries a risk of creating sparks, which could ignite fuel fumes.
• Make sure to depressurise the fuel system before removing any fuel lines to avoid getting sprayed in the face.
• All hose fittings are quick disconnects. Two of them have locks that need to be removed.
• There is also a crossover tube that connects both sending units in the tank that must be disconnected.
• The sensors are locked in place by a tab. Depress the tab to slide the sensors off.
• A Dorman kit is available for this job that comes with both sensors and new seals.
• Let the car sit overnight before working on it if possible, to ensure that the fuel system is fully depressurised.
• When removing the lock ring, a large rubber strap wrench can be used to twist it off.
• Cut the carpet a little to get better access to the sending unit covers.

Replacing the fuel level sensor

The fuel level sensor in the Hyundai Santa Fe is located inside the fuel tank. It has a float, actuating rod, and a resistor that sends signals to the fuel gauge system. When problems arise with the fuel level sensor, it is recommended to bring the car in for a professional check-up to ensure the fuel level indicator and warning systems are correct and timely.

Step 1: Purchase the correct parts

Before beginning the replacement, you will need to purchase the correct parts. The part numbers for the fuel level sensors are 944300w000 and 944600w000. It is recommended to replace both sensors at the same time. You will also need to purchase the OTC-6599 universal fuel sending unit wrench to remove the cover.

Step 2: Remove the rear seats

The first step is to remove the rear 60/40 seats. There are eight bolts (four per seat) holding the seats in place. To access the bolts, you will need to pop off the plastic covers. Once the covers are removed, tilt the seat back forward until you have enough room to get a socket through the gap.

Step 3: Access the fuel pump service cover

Remove the carpet patches to expose the fuel pump service cover. The bolts holding the cover in place are marked with red circles. Gently pry up the cover with a screwdriver or pry bar, being careful not to warp it.

Step 4: Disconnect the wiring harness

Release the wiring harness connector under the service cover and push the rubber grommet out. Feed the harness back under the carpet towards the driver's side fuel pump to provide slack for the next steps.

Step 5: Depressurize the fuel system

Before removing any fuel lines, it is important to depressurize the fuel system. Start the engine and let it run until it stalls to release the pressure. Place rags around the area to soak up any residual gas.

Step 6: Remove the fuel lines

Remove the quick-release button in the square and pull out the fuel line. Position the OTC-6599 tool in the notches and use a breaker bar to turn counter-clockwise and loosen the ring. Remove the second fuel line by pushing down the clip.

Step 7: Remove the fuel pump

Carefully lift the fuel pump out about halfway. You may need to turn/angle it to get it out. Be gentle and pay attention to how the wire is wrapped around the pump. Have a helper hold the pump while you change the sensor.

Step 8: Replace the fuel level sensor

The sensor slides in and out and is held in place by a notch. Simply slide it out and replace it with the new sensor. Make sure the new sensor is positioned correctly before sliding it into place.

Step 9: Reinstall the fuel pump and cover

Reinstall the fuel lines and rings, making sure to hear a loud click indicating that the covers are fully locked and the tank can be pressurized. Apply black silicone to the service cover and place a weighted object on top while the silicone sets.

Tips

• It is highly recommended to purchase the OTC-6599 tool for removing the cover. While it is possible to use a hammer and screwdriver, this method can be dangerous and may damage the cover.
• Make sure to clean up any debris in the area before beginning the replacement to avoid anything falling into the tank.
• Be very careful with the plastic retaining clips for the vapor recovery tubes as they can break easily.
• It is a tight squeeze to get the pump out, so take your time and be gentle to avoid damaging any components.
• Vacuum the area again after removing the ring to ensure no debris falls into the tank.
• The sensors are locked in place by a tab. Depress the tab to slide the sensors off.

Reinstalling the assembly

Now that you've removed the old fuel level sensor assembly, it's time to install the new one. Here's a step-by-step guide to help you through the process:

• Prepare the new assembly: Before you begin, make sure you have the correct replacement parts for your 2008 Santa Fe. You will need a new fuel level sensor assembly, which typically includes the sensor itself and a new O-ring or gasket.
• Clean the fuel tank: Before installing the new assembly, it's important to clean the fuel tank to remove any debris or residue. Use a vacuum to clean out any dirt or loose particles from the tank. You can also use a wire brush or a clean cloth to wipe down the area where the new assembly will be installed.
• Position the new assembly: Carefully lower the new fuel level sensor assembly into the fuel tank. Make sure it is properly aligned and seated securely in the tank.
• Reconnect the wiring harness: Locate the wiring harness that connects to the fuel level sensor. Plug it back into the new assembly, ensuring a secure connection.
• Reattach the fuel lines: Reconnect the fuel lines that were previously disconnected. Be very careful when handling the fuel lines, as they may still contain some fuel. Double-check that all connections are secure to prevent leaks.
• Reinstall the fuel pump fuse or relay: If you removed the fuel pump fuse or relay earlier, now is the time to reinstall it. This will restore power to the fuel pump and allow it to start functioning again.
• Test the fuel level sensor: Once everything is connected, turn on the ignition and check the fuel gauge. The needle should move accordingly as you add fuel to the tank. If the gauge is still not working properly, double-check all your connections and ensure the sensor is properly seated.
• Reinstall the rear seat: Finally, put the rear seat back in place by reversing the steps you took to remove it. Secure all bolts and make sure the seat is properly anchored.

By following these steps, you should be able to successfully reinstall the fuel level sensor assembly in your 2008 Santa Fe. Remember to work carefully and safely when handling fuel system components, and always refer to your vehicle's repair manual for specific instructions and safety precautions.

Frequently asked questions