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HOMESERVICE MANUALSHYUNDAI2003SANTA FE GLS, 2.7 D, FWDREPAIR AND DIAGNOSISENGINE PERFORMANCEENGINE CONTROL SYSTEMSFUEL SYSTEM (2.7L)FUEL DELIVERY SYSTEMFUEL TANKFUEL PRESSURE TEST
2003 Hyundai Santa Fe GLS, 2.7 D, FWD

Fuel Pressure Test

2003 Hyundai Santa Fe GLS, 2.7 D, FWDSECTION Fuel Pressure Test
  1. Reduce the internal pressure of the fuel pipes and hoses by the following procedures.
    • Disconnect the fuel pump harness connector after removing the rear seat cushion.
    • Start the engine and after it stalls, turn the ignition switch to the OFF position.
    • Disconnect the battery negative (-) terminal.
    • Connect the fuel pump harness connector.
  2. Remove the bolt connecting the fuel line to the fuel filter.
    CAUTION: Cover the hose connection with a shop towel to prevent splashing of fuel caused by fuel residual pressure in the fuel line.
  3. Using the fuel pressure gauge adapter, install the fuel-pressure gauge to the fuel filter. Tighten the bolt to the specified torque.

    Tightening Torque 

    Fuel pressure gauge to fuel filter: 25-35 Nm (250-350 kg.cm, 18-26 lb-ft)

    Fig 1: Identifying Fuel Pressure Gauge Adapter
    G00791530Courtesy of HYUNDAI MOTOR CO.
  4. Connect the battery's negative (-) terminal.
  5. Apply battery voltage to the terminal for the pump drive and activate the fuel pump: then, with fuel pressure applied, check that there is no fuel leakage from the pressure gauge or connection part.
  6. Start and run the engine at curb idle speed.
  7. Disconnect the vacuum hose from the pressure regulator, and plug the hose end. Measure the fuel pressure at idle.

    Standard value: 

    320-340 kPa (3.26-3.47 kg/cm2 , 37 psi)

    Fig 2: Plugging Vacuum Hose
    G00791531Courtesy of HYUNDAI MOTOR CO.
  8. Measure the fuel pressure when the vacuum hose is connected to the pressure regulator.

    Standard value: 

    Approx. 255 kPa (2.57 kg/cm2 , 37 psi)

  9. If the results of the measurements made in steps (7) and (8) are not within the standard value, use the table below to determine the probable cause, and make the necessary repairs.
    Fig 3: Fuel Pressure Test Table
    G00791533Courtesy of HYUNDAI MOTOR CO.
  10. Stop the engine and check for a change in the fuel pressure gauge reading, which should hold for approximately 5 minutes. If the gauge indication drops, observe the rate of drop. Determine and remove the causes according to the following table.
    Fig 4: Fuel Pressure Drop Test Table
    G00791534Courtesy of HYUNDAI MOTOR CO.
  11. Reduce the pressure in the fuel line.
  12. Disconnect the hose and the gauge.
    CAUTION: Cover the hose connection with a shop towel to prevent splashing of fuel caused by fuel residual pressure in the fuel line 
  13. Replace the O-ring of the hose.
  14. Connect the fuel hose to the delivery pipe and tighten with the specified.
  15. Check for fuel leakage.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.