← Santa Fe Hyundai Santa Fe repair manuals →
Autopapyrus · Hyundai Santa Fe 2.2 CRDi D4HB (2022)
https://autopapyrus.com/guides/hyundai/santa-fe/in-tank-fuel-pump-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Hyundai Santa Fe 2.2 CRDi D4HB (2022): In-Tank Fuel Pump Replacement

The 2022 vehicle with the D4HB engine is a diesel. The high-pressure pump on the engine pressurizes the fuel in the rail. The tank contains an electric low-pressure lift pump, which is part of a module together with the fuel level sensor. You can often reach the module through a service access panel under the rear seat, without removing the tank. The exact access layout for your trim level may differ, so the steps below are general.

DifficultyMedium Time2-3 hours Steps18

Diagram: where the fuel tank service hatch is and how to reach the pump

Hatch in the floor under the rear seatFloor under the seat, carpet folded back1Remove the hatch cover2Unscrew the ring3Disconnect the connector4Press the lock and pullTop view of the module in the tankTap to enlarge
  1. 1Hatch cover in the floor above the tank. Fold back the carpet under the rear seat, wipe the cover and remove it.
  2. 2Locking ring of the module with tabs. Unscrew it with a special tool or tap it round with a screwdriver using the tabs, without damaging the plastic.
  3. 3Electrical connector of the pump. Disconnect it.
  4. 4Quick-release fitting and fuel tube. Press the lock and pull the tube off; put a rag under it as a little fuel will spill.

Parts

3
№PartAlternatives
01 Low-pressure fuel pump module (in-tank lift pump), Santa Fe IV TM 2.2 CRDicomplete assembly AlternativesVDOHellaRidex
02 Electric fuel pump (pump only, from the module)alternative to the complete module AlternativesVDOHellaRidex
03 Fuel pump module cover seal ring

Tools

8
  • Socket set and ratchet
  • screwdrivers
  • wide flat-blade screwdriver or a dedicated pump cover lock ring removal tool
  • hose clamp pliers
  • fuel container
  • gloves
  • fire extinguisher nearby
  • multimeter
There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes and 6 more. See manuals →

Step by step

18 steps
  1. Make sure the pump is actually faulty. Typical symptoms: the engine cranks but does not start, loss of power, whining from the tank area, low fuel pressure fault codes. Check the fuel pump fuse and relay (fuse box under the dash on the driver's left) and check for power at the pump connector. This way you won't remove a good pump.
  2. Work outdoors or in a well-ventilated area, away from open flames. Ideally the tank should be no more than half full.
  3. Turn the ignition off and disconnect the negative battery terminal. Wait for all control modules to shut down, usually a few minutes.
  4. Relieve the residual pressure in the low-pressure line. First disconnect the pump connector, then start the engine once or crank it with the starter to use up the fuel in the line. If the engine will not start, just place rags and a container under the fittings. Do not touch the high-pressure fuel lines on the engine (from the high-pressure pump to the rail and injectors). The pressure there stays extremely high.
  5. Remove the rear seat or fold up its cushion, depending on your vehicle's design. Peel back the floor carpet under the seat and locate the service access panel above the tank.
  6. If there is no access panel, you will need to lower the tank: remove the underbody shield, disconnect the filler neck and hoses, support the tank with a jack and a wooden block, remove the retaining straps and carefully lower the tank. Only attempt this method if you have a lift or a pit and a helper.
  7. Wipe the access panel and the module flange clean. Dirt must not get into the tank. Remove the service cover.
  8. Disconnect the pump's electrical connector. If the module has other connectors or lines (a pressure sensor or a vacuum line), photograph their positions and disconnect them.
  9. Disconnect the quick-release fitting on the supply line. Press the retainer and pull the line off. Hold a rag underneath, since a little fuel will spill. If the module has a return line, disconnect it as well.
  10. Unscrew the lock ring or module cover. The ring can be removed with a dedicated removal tool. If you don't have one, carefully tap the ring clockwise and counterclockwise with a wide flat-blade screwdriver against its tabs, without damaging the plastic.
  11. Slowly lift the module out, tilting it at an angle so you don't bend the fuel level sensor float. Drain the remaining fuel from the module into a container.
  12. If necessary, replace the pump separately: disconnect the suction line and the strainer (filter sock) at the bottom, then remove the pump from its holder. Photograph the positions of the hoses and wires. If the pump is sold only as part of the module, replace the entire module. While you're at it, clean or replace the inlet strainer.
  13. Inspect the inside of the tank. If there is a lot of rust, dirt or water on the bottom, that is a reason to clean the tank. Otherwise the new pump will soon fail. If the fuel filter on the engine is contaminated, replace it too.
  14. Install a new cover seal ring (do not lubricate the ring; it must go in dry and clean). Lower the module into the tank, aligning the marks or tabs with the seats. The float must move freely.
  15. Screw the lock ring down until it stops and tighten it evenly. Use the tightening torque specified by the manufacturer; it must not be cocked. Connect the fuel line and make sure the fitting has clicked into place. Tug on the line by hand. Plug in the connector.
  16. Reinstall the service cover, carpet and seat (or raise the tank and tighten the straps, reinstalling the hoses and shield). The tightening torques for the tank and shield fasteners and for the lock ring are approximate; check the exact values against the manufacturer's specifications.
  17. Reconnect the battery. Turn the ignition on and off several times so the pump primes the system. Then start the engine, possibly after several attempts, since the circuit may have run dry. Check the connections for fuel smell and leaks. Make sure the fuel level sensor reads correctly.
  18. Check the fault code memory and, if needed, clear the codes with a diagnostic scan tool. Take a test drive.

Common mistakes and warnings

  • Working on the fuel system is a fire hazard: diesel fuel burns, and the pressure in the rail and at the high-pressure pump is very high (hundreds of bar), so the high-pressure lines must never be opened
  • Do not smoke or work near sources of sparks
  • If you have no experience working on fuel systems or do not have a lift, take the vehicle to a repair shop
  • Dispose of used fuel and rags properly