Replacing Fuel Sensors In Your 2008 Hyundai Santa Fe

The fuel level sensor in the 2008 Hyundai Santa Fe is located inside the fuel tank and is designed to determine the amount of fuel inside the tank. The sensor features a float, actuating rod, and a resistor that send signals to the fuel gauging system. When the sensor goes bad, the engine control module signals the driver by turning on the check engine light. Poor fuel economy, hard starting of the engine, engine misfire, and poor performance may also be observed.

To replace the fuel level sensor, you will need to remove the rear seat and cut the carpet and padding to access the fuel tank. Next, relieve the fuel system pressure and disconnect the fuel lines and wiring. Remove the retaining bolts and carefully lift the fuel pump/fuel level sensor assembly from the fuel tank. Install the new fuel level sensor and reverse the removal process.

It is recommended to replace both fuel level sensors at the same time to avoid further issues. The average cost for a Hyundai Santa Fe Fuel Pressure Sensor Replacement is between $226 and $247, with labor costs estimated between $79 and $100, and parts typically priced around $147.

Disconnecting the main fuel line

Before beginning, ensure you have the necessary tools, including a suitable fuel line disconnect tool, and create a safe working environment by parking the vehicle on a level surface, engaging the parking brake, and placing wheel chocks to prevent accidental movement.

Prepare the Work Area:

• Remove the rear seats by unbolting them and carefully setting them aside. This will provide access to the fuel pump service cover.
• Locate and remove the fuel pump service cover by gently prying it up with a screwdriver or pry bar. Take care not to warp or damage the cover, as it needs to seal properly when reinstalled.
• Once the cover is removed, you will have access to the fuel pump and associated components.

Relieve Fuel System Pressure:

Start the engine and let it run until it stalls, ensuring that the fuel system is depressurized. This is an important safety step before disconnecting any fuel lines.

Disconnect the Main Fuel Line:

• Prepare rags or absorbent materials to catch any residual fuel that may spill during the disconnection process.
• Identify the main fuel line connected to the fuel pump. It is usually secured with a quick-release mechanism or a clamp.
• Using the appropriate tool, carefully release the quick-release button or loosen the clamp, depending on your vehicle's configuration.
• Gently pull the fuel line away from the fuel pump to disconnect it. Place the disconnected fuel line aside, ensuring it is secure and does not pose a tripping hazard.

Secure the Work Area:

Before proceeding further, ensure that all fuel lines are properly secured and that there are no leaks. Absorbent rags can be used to catch any residual fuel drips.

Remember to work cautiously and refer to a qualified mechanic or a repair manual for specific details pertaining to your vehicle. Working with fuel systems can be dangerous, so ensure you have the necessary knowledge, skills, and tools before proceeding.

Removing the plate cover

To remove the plate cover, you will need to carefully pry and lift off the access covers. The cover is held down with an adhesive, so be careful not to bend the panel—it needs to stay flat to seal again.

It is highly recommended that you buy the correct tool for this job: the OTC-6599 universal fuel sending unit wrench, available on Amazon. This will make removing the locking rings much easier than banging on them with a screwdriver or similar tool, without causing damage or creating a spark that could ignite any gas fumes.

With the tool, you will need to apply considerable torque to get the cover off. You may even need to beat the wrench with a rubber mallet.

The assemblies are spring-loaded, so you can push down a little and rotate them during removal and reinstallation. It's a tight squeeze at times, so take your time.

Removing the fuel pump/level sensor assembly

To remove the fuel pump/level sensor assembly in a 2008 Hyundai Santa Fe, you will need to set aside 4-6 hours and gather the necessary tools and materials, including a rubber mallet, a breaker bar, and the OTC-6599 universal fuel sending unit wrench. Here is a step-by-step guide to help you through the process:

Step 1: Remove the Seats and Access Panels

Use a socket to remove the bolts holding the seats in place. There are four bolts per seat, and the front bolts are covered by plastic, which you will need to pop off to access the bolts. Tilt the seat back forward until you have enough space to fit a socket through the gap.

Step 2: Remove the Carpet Patches

Remove the carpet patches to expose the fuel pump service cover. The carpet patches are usually held in place with velcro.

Step 3: Access the Fuel Pump Service Cover

Gently pry up the fuel pump service cover with a screwdriver or pry bar. Go around slowly and carefully to avoid warping the cover. The cover is typically held in place with black silicone glue.

Step 4: Disconnect 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.

Step 5: De-pressurize the Fuel System

Start the engine and let it run until it stalls to de-pressurize the fuel lines. Be prepared for some fuel spillage when disconnecting the main fuel line on the pump. Pack the area with a rag before disconnecting the line.

Step 6: Remove the Fuel Lines

Using the OTC-6599 tool, position the breaker bar in the notches of the ring that holds the pump in place. Apply significant force to loosen the ring, and then remove it. Detach the second fuel line by pushing down on the clip.

Step 7: Remove the Fuel Pump Assembly

With the help of another person, carefully lift the fuel pump assembly out of the tank. Be gentle and pay attention to how the wire is wrapped around the pump.

Step 8: Replace the Fuel Level Sensor

Have one person hold the pump while the other replaces the fuel level sensor. The sensor slides in and out and is held in place by a notch. Install the new sensor in the same position as the old one, ensuring it is not installed upside down.

Step 9: Reassemble the Components

Reinstall the fuel lines, making sure to attach the clips securely. Reassemble the fuel pump service cover, applying black silicone to the cover before placing weighted objects on top to help it set. Finally, reinstall the seats and carpet patches.

Note: It is recommended to replace both fuel level sensors at the same time to avoid further issues. Additionally, some sources suggest inspecting and cleaning the fuel pump inlet strainer if necessary.

Replacing the fuel level sensor

The fuel level sensor in Hyundai Santa Fe vehicles is located inside the fuel tank. It consists of a float, an actuating rod, and a resistor that sends signals to the fuel gauge system, allowing you to monitor the remaining fuel volume through the instrument panel. When problems arise with the fuel level sensor, it is advisable to have the car checked by a professional to ensure accurate and timely fuel level indication and warning.

Step 1: Prepare the necessary tools and parts

You will need the following tools and parts to replace the fuel level sensor:

• A new fuel level sensor
• A rubber mallet
• A screwdriver
• A wrench
• A breaker bar
• Rags
• A vacuum

It is highly recommended to purchase the correct tool for removing the locking rings, such as the OTC-6599 universal fuel sending unit wrench. This tool can be purchased online or from automotive parts stores.

Additionally, you may need to trim the carpet for easier access to the fuel pump service cover.

Step 2: Access the fuel pump

Start by removing the rear seats. This will provide access to the fuel pump service cover. There are typically eight bolts holding the seats in place. To access the front bolts, you may need to pop off plastic covers.

Once the seats are removed, carefully pry and lift off the access covers using a screwdriver or pry bar. Be gentle to avoid bending or damaging the panel. The cover is usually held in place with an adhesive, so take care not to break the seal.

Step 3: Disconnect the wiring harness

Locate the wiring harness connector under the service cover and carefully disconnect it. You may need to push the rubber grommet out of the service cover to access the wires fully.

Step 4: De-pressurize the fuel system

Before proceeding, it is crucial to relieve the residual pressure in the fuel system. Disable the fuel pump by removing the fuse, and then crank the ignition. Disconnect the battery for safety.

Step 5: Remove the fuel lines

There are two fuel lines connected to the fuel pump. First, press the "button" or quick-release mechanism in the square connector to detach the first fuel line. Then, using the appropriate tool, carefully loosen and remove the locking ring that holds the fuel pump assembly in place. The pump is spring-loaded, so it may pop up slightly when released.

Use rags to soak up any residual fuel in the lines and vacuum the area to ensure no debris falls into the tank.

Step 6: Remove the old fuel level sensor

With the fuel lines disconnected, carefully lift the fuel pump assembly out of the tank. Pay attention to the orientation of the sensor and how the wire is wrapped around the pump to facilitate reinstallation.

The fuel level sensor should slide in and out of the pump assembly and is typically held in place by a notch. Gently remove the old sensor and set it aside.

Step 7: Install the new fuel level sensor

Install the new fuel level sensor by sliding it into the notch in the fuel pump assembly. Ensure it is positioned correctly and securely locked in place.

Step 8: Reassemble the fuel pump

Reattach the fuel lines, ensuring all connections are secure. Reinstall the locking ring using the appropriate tool and torque it to the specified tightness.

Step 9: Reinstall the fuel pump assembly

Carefully lower the fuel pump assembly back into the tank, ensuring it is properly seated and aligned. Reconnect the wiring harness and secure the fuel pump service cover. If necessary, apply a fresh bead of black silicone to ensure a tight seal.

Step 10: Test the fuel gauge

Start the engine and check the fuel gauge to ensure it is functioning correctly. You may need to drive the car for a short distance to allow the gauge to calibrate accurately.

Reinstalling the fuel pump/level sensor assembly

Now that you've removed the fuel pump/level sensor assembly, it's time to reinstall the new one. Here's a step-by-step guide on how to do it:

• Prepare the new assembly: Check that you have the correct replacement parts and that they are in good condition. Make sure the new fuel pump/level sensor assembly is similar to the one you removed.
• Clean the area: Before installing the new assembly, it's important to clean the area thoroughly. Use a vacuum to remove any debris or residue that may have accumulated. Pay special attention to the area around the fuel pump inlet strainer and make sure it is free of any dirt or debris.
• Reconnect the fuel lines: Attach the fuel lines back to the fuel pump. Be careful not to overtighten the connections to avoid any leaks.
• Secure the assembly: Place the new fuel pump/level sensor assembly back into the fuel tank. Make sure it is securely fastened and positioned correctly.
• Reattach the wiring: Connect the wiring harness back to the fuel pump/level sensor assembly. Ensure that all connections are secure and correct.
• Reinstall the fuel tank: If you had to remove the fuel tank to access the assembly, now is the time to reinstall it. Follow the appropriate safety procedures and ensure that all connections are secure before closing up the vehicle.
• Test the system: Once everything is connected and secured, start the engine and check for any leaks or unusual noises. Pay attention to the fuel gauge and ensure that it is functioning correctly.
• Reset the system: In some cases, you may need to reset the fuel system after replacing the fuel pump/level sensor assembly. This can be done by disconnecting the battery for a few minutes and then reconnecting it.
• Test drive: Take the vehicle for a test drive to ensure that the new assembly is functioning correctly. Pay attention to the fuel gauge and any warning lights on the dashboard.

By following these steps, you can confidently reinstall the fuel pump/level sensor assembly in your 2008 Hyundai Santa Fe. Remember to work in a well-ventilated area and take the necessary safety precautions when working with fuel systems.

Frequently asked questions