Hyundai Ioniq: Fuel Delivery System / Fuel Pump. Repair procedures

Hyundai Ioniq (AE) 2017-2025 Service Manual / Engine Control/Fuel System / Fuel Delivery System / Fuel Pump. Repair procedures

Inspection

[Fuel Sender]

Using an ohmmeter, measure the resistance between terminals 1 and 6 of sender connector (A) at each float level.

Pin No	Discription
1	Fuel sender ground
2	Fuel pressure sensor (FPS) signal input
3	Fuel pressure sensor (FPS) ground (-)
4	Ground
5	CAN [Low]
6	Fuel sender signal
7	-
8	Fuel pressure sensor (FPS) Power supply (+5V)
9	CAN [High]
10	Battery power (B+)

Also check that the resistance changes smoothly when the float is moved from "E" to "F".

Position	Resistance (Ω)	Capacity (ℓ)
E	298 - 305	2.3
1/2	80 - 82	22.5
F	14 - 16	44.1

Removal

1.	Turn the ignition switch OFF and disconnect the battery negative (-) cable.

2.	Remove the rear seat cushion. (Refer to Body - "Rear Seat Assembly")

Remove the fuel pump service cover (A).

•	When reinstalling a protective cover for a fuel pump, remove the existing butyl tape and apply a new one.

•	Before assembling the protective cover, ensure that the temperature of the butyl is about 30°C using a hair dryer or a heat gun.

•	When installing the protective cover for the fuel pump, pay attention to the installation direction of the grommet and the protective cover.

–	The arrow (A) should be in the forward direction of the car.

–	Align the bulging part of the vehicle body (B) with the hole of the protective cover.

–	Align the bulging part of the grommet (C) with the bulging part of the protective cover.

4.	Disconnect the fuel pump control module connector (A).

5.	Disconnect the fuel pressure sensor connector (B).

6.	Disconnect the fuel feed tube quick-connector (C).

Remove the fuel pump locking ring (B) with SST (A) [SST.: 09310-F8100].

•	When removing the plate cover, be careful not to damage the fuel tank and fuel pump.

•	When removing the plate cover, press the upper area with hand and rotate the wrench counter clockwise.

8.	Remove the fuel pump (A).

Installation

1.	Install in the reverse order of removal.

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