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Fuel Pressure Service Tools/Testing Procedure (2-09-001)

Publication date: 1990-07-01
Reference number: 2-09-001

FUEL PRESSURE SERVICE TOOLS/TESTING PROCEDURE

FUEL PRESSURE SERVICE TOOLS/TESTING PROCEDURE

TECHNICAL SERVICE BULLETIN

Reference Number(s): 2-09-001, Date of Issue:  July, 1990

FUEL PRESSURE TESTING SST

Model: 1990 Sonata & Excel

Group: Special Service Tools

Number: 2-09-001

Date: July, 1990

Vol: 2

ILLUSTRATIONS

Fig 1: Fuel Pressure Testing Components
G93I54294
Fig 2: Removal of Upper Eye Bolt-Excel
G93J54295
Fig 3: Installation of Fuel Pressure Gauge to Fuel Filter-Excel
G93A54296
Fig 4: Disconnecting Vacuum Hose From Pressure Regulator - Excel
G93B54297
Fig 5: Measuring Fuel Pressure - Excel
G93C54298
Fig 6: Placement of Fuel Pressure Gauge Adapter-Sonata
G93D54299
Fig 7: Installation of Fuel Pressure Gauge to Fuel Filter-Sonata
G93G54300
Fig 8: Disconnecting Vacuum Hose From Pressure Regulator & Plugging End (Sonata)
G93H54301
Fig 9: Measuring Fuel Pressure (Sonata)
G93I54302

SERVICE INFORMATION

The following components comprise the 1990 Excel and 1990 Sonata Special Service Tool for performing the fuel pressure test.

See Fig 1 full procedures have been added to this bulletin for your convenience.

SPECIAL SERVICE TOOLS INFORMATION

Key No. Tool Name Tool No. Application Model
1 FUEL PRESSURE GAUGE & HOSE 09353-24100 ALL
2 FUEL PRESSURE GAUGE CONNECTOR 09353-24000 ALL
3 FUEL PRESSURE GAUGE ADAPTER 09353-24200 EXCEL, SCOUPE, SONATA
4 FUEL PRESSURE GAUGE ADAPTER 09353-33000 SONATA V6
NOTE: Kent-Moore tool number J-38228 includes tool no. 09353-24100, 09353-24000 and 09353-24200.

1990 HYUNDAI EXCEL FUEL PRESSURE TESTING PROCEDURES

  1. Reduce the internal pressure for the fuel pipes and hoses by the following procedures.
    1. Disconnect the fuel pump harness connector at the rear of the fuel tank.
    2. Start the engine and after it stalls, turn the ignition switch to off.
    3. Disconnect the battery negative (-) terminal.
    4. Connect the fuel pump harness connector.
  2. Remove the upper eye bolt while holding the fuel filter nut securely. (See Fig 2 )
  3. Using the fuel pressure gauge adapter (09353-24000), install the fuel pressure gauge to the fuel filter. Tighten the bolt to specified torque. See Fig 3 . Tightening Torque: Fuel Pressure Gauge to Fuel Filter 18-25 lb.ft. (25-34 Nm, 250-350 kg.cm)
  4. Connect the batteries negative (-) terminal.
  5. Start Engine.
  6. Disconnect the vacuum hose from the pressure regulator, and plug the hose end. Measure the fuel pressure at idle. Standard value 330-350kPa (3.36-357kg/cm2 ,47-50psi)
  7. Measure the fuel pressure when the vacuum hose is connected to the pressure regulator. Refer to Fig. Fig 5 . Standard value Approx 270 kPa (2.75 kg/cm2 , 39 psi)
  8. If the results of the measurements made in steps (6) and (7) are not within the standard value, use the table below to determine the probable cause, and make the necessary repairs.
    Fig 10: FUEL PRESSURE TROUBLESHOOTING TABLE I
    GB0049620
  9. 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 11: FUEL PRESSURE TROUBLESHOOTING TABLE II
    GB0049621
  10. Reduce the fuel pressure in the fuel line.
  11. Disconnect the fuel pressure gauge from the adapter bolt. Remove the adapter bolt and replace with the original bolt and tighten down.
  12. Check for fuel leaks. Apply battery voltage to the fuel pump drive terminal to operate the fuel pump. With pressure, check the fuel line for leaks.

1990 SONATA FUEL PRESSURE TESTING PROCEDURES

  1. Reduce the internal pressure of the fuel pipes and hoses by the following procedures.
    • Disconnect the fuel pump harness connector at the fuel tank rear side.
    • Start the engine and after it stops by itself, turn the ignition switch to OFF.
    • Disconnect the battery negative (--) terminal.
    • Connect the fuel pump harness connector.
  2. Remove the bolt connecting the fuel filter hose to the delivery pipe.
  3. Using the fuel pressure gauge adapter (09353-24000), See Fig 6 , install the fuel pressure gauge to the fuel filter. See Fig 7 . Tighten bolt to specified torque.
  4. Connect the battery's negative (-) terminal.
  5. Start Engine
  6. Disconnect the vacuum hose from the pressure regulator, and plug the hose end. See Fig 8 . Measure the fuel pressure at idle. Standard value 320-340kPa (3.26-347 kg/cm, 46 49 psi)
  7. Measure the fuel pressure when the vacuum hose is connected to the pressure regulator. Standard value 270 kPa (2.75 kg/cm2 , 39 psi)
  8. If the results of the measurements made in steps (6) and (7) are not within the standard value, use the table below to determine the probable cause, and then make the necessary repair.
    Fig 12: FUEL PRESSURE TROUBLESHOOTING TABLE I
    GB0049622
  9. 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 13: FUEL PRESSURE TROUBLESHOOTING TABLE II
    GB0049623
  10. Reduce the fuel pressure in the fuel line.
  11. Disconnect the fuel pressure gauge from the adapter bolt. Remove the adapter bolt and replace with the original bolt and tighten down.
  12. Check for fuel leaks. Apply battery voltage to the fuel pump drive terminal to operate the fuel pump. With pressure, check the fuel line for leaks.
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