DIY 2005 Hyundai Tucson Fuel Pump Replacement

0:38 Removing the back seat
1:24 Removing access plate
2:10 Unplugging the electrical
2:22 Unplugging fuel pump relay
3:01 Disconnecting the negative battery terminal
3:34 Unplugging fuel lines
4:16 Removing fuel pump housing retaining bolts
5:12 Removing the old fuel pump
5:30 Pumping gas out of the tank
6:40 Inserting new fuel pump
7:12 Reconnecting the fuel lines
This took me about 3 1/2 hours.
I got my Delphi fuel pump/filter housing from
rockauto.com
“Even a blind squirrel finds a nut now and then” and that’s my motto for these DIY videos. I am not a professional in any area covered in these videos, just an average guy trying to save money by doing things on my own. Obviously I only post the videos if I was successful, and so I hope I can help you out. I made these videos mainly because I couldn’t find one for my specific project on KZbin.
Ask any questions you have in the comments, but just know I don’t really know anything & just figured it out along the way. If you know anything about the project in this video or have experience yourself, please by all means comment and tell me what I should have known or done differently!

[@jamtiludrop]

Noticed you used a shop vac when the pump was already removed. Gasoline vapors are incredibly volatile and you were sucking them into a chamber which has an electric motor running inches away from the gasoline fumes. There is a continuous spark in a running motor between the brushes and the armature. If the fumes had ignited, they could have flashed all the way through the hose and into the gas tank. You're lucky to be here my friend.

[@240_Jordy]

Thank you for your time and effort making this video, I was dreading replacing the fuel pump in my wife's car until I saw how easy you made it look. I figured I would be dropping the tank, thank you Hyundai for having the access panel.

[@rawar777joshanderson]

glad to help!

[@RobbieKing]

Thank you for the video... I have 2005 Tucson as well... You saved me a boat load of money!! Again thank you! The Tucson is back on the road.

[@rawar777joshanderson]

Heck yes!!

[@1trackmindsantos]

Nice, your reference was spot on, I went with the Delphi also. That had to be the easiest fuel pump I've ever had to replace.

[@rawar777joshanderson]

Dang, if this one is easy I'd hate to see others, haha

[@1trackmindsantos]

Like imagine 25 gal. tank that's straps from underneath that requires drop tank part way, then disconnect lines and wiring, then drop the rest of the way then drag out from beneath, then start replacing pump. Sucks so bad to put back together. Your videos matter! Live long.

[@xcodychaosx]

Seat belt works decent in place of the bungee also if you remove the fuse you dont need to un hook the battery but thanks for the video helped a bunch finished in about 45 minutes easy peasy after getting youtube certified :b

[@rawar777joshanderson]

That makes sense! I'll try that next time (hopefully there won't be a next time)

[@brettnicholas3190]

1 suggestion. Plug everything back in/on. THEN start the car. Then put carpets and seats back. If the car doesn’t start, at least you still have access to the pump in case you missed something.

[@rawar777joshanderson]

That's a good idea

[@ishoshamo8949]

Hey, thanks man, really admire the work you did and helped me out a lot. It worked for my 2006 Kia Sportage.

[@stefansammi8197]

Thank you for taking the time to post this video - excellent

[@alandonly]

Vacuuming at bare opening of fuel tank is dangerous. Vacuum cleaners generate a lot of static electricity in the plastic hose. Could have the ignited fuel. Orange clips aren't to be removed. They're a safety clip - just lift perpendicular to the direction you pull hose outlet. Otherwise thanks for the video!!

[@rawar777joshanderson]

Thanks for the tip and yeah, for extra precaution for anyone following this, that should be noted. However, my dad, as a career welder on heavy equipment at a coal mine always assured me that gas fumes dissipate quickly in open air and are only volatile in closed areas. But, as with any KZbin tutorial, attempt at your own risk! And thanks for the tip about the orange clip.

[@Timmatheterrible]

Fantastic help. Thank you for posting this.

[@MSneberger]

Dealer just quoted me $800 to replace the fuel pump on a 2005 Hyundai. Service Writer said the tank had to be dropped out to do the job (which I guessed was bunk based on pretty much every other car made in the last 20 years). Everything dealers service departments say is a lie. Really sad. I'll do it myself thank you.

[@windmountain8852]

Dealer sucks, they suck blood. Once the dealer charged my wife $60 to replace the cabin filter. I was pissed.

[@georgeramsey2827]

Some cars do need to have the tank dropped but but obviously not all. Some dealerships charge the same for every model no matter if its easier or not.

[@MSneberger]

@@georgeramsey2827 BTW, IIRC I bought a whole pump/sending unit on RockAuto for $55 and spent a few hours leisurely installing it. Unfortunately, did not fix the very random failure to start issue, but at least saved some $$$ and got to use some skills.

[@highlightedcomment]

Can also be a air filter assembly having a loose fitting or a ground wire...

[@MrJx4000]

So here I am in late September 2024, looking to R/R my 2005 Tucson 2.0L engine, fuel pump. I have just over 351,000 kms (about 220,000 mi) on this baby, the engine and trans. run great and I think the fuel pump finally gave out--it wont start at all, first time ever since 2010 when I bought it. I could always hear the pump turn on briefly when I turned the ignition to ON, just before turning over the starter motor. Yesterday, it was dead silent. How do you know if the relay/fuse isn't bad?

[@rawar777joshanderson]

@@MrJx4000 do you know how to check a fuse? & do you have the manual that tells what each fuse is for? I would check that first.

[@MrJx4000]

@@rawar777joshanderson, yes I know how to check a fuse; I did not find any in that little side panel on the left-side of the dashboard. But I did find the relay under the hood and see that there are several others with the same number so I'll swap 'em out tomorrow to see what happens. I'll let you know. Great video again.

[@MrJx4000]

So I just tried swapping out the relays and it did not work. It's the original fuel pump with 220k miles on it. I used to hear a faint buzzing sound when I turned the key to ON, before turning over the starter motor. I don't hear that now and it does not start, so the fuel pump must be toast.

[@rawar777joshanderson]

@@MrJx4000 Thanks, I'll be curious to know what works for you!

[@MrJx4000]

@@rawar777joshanderson, Oct 12th, looking more and more like it's not a fuel pump problem but wiring harness corrosion to that relay box under the hood. Pulled the MAIN relay to see corrosion on one terminal and then looked at its connector to see more corrosion. I cleaned off the relay corrosion and then sprayed a dab of penetrating fluid into the female connector. My battery's been charging up all day yesterday and today but with a 35% charge, I tried starting it and it almost did. I'll pull apart that relay box and come back with pictures of course.

[@waynepolkus488]

Hi, great video but I have a question... I've done quite a few fuel pumps in by time but never on a Hyundai... Why drain the tank? Wouldn't just replacing the fuel pump be enough? Just seems like a waste of time and money.

[@rawar777joshanderson]

Honestly I drained it because I saw a more professional video they did it. I don't really know why except maybe to get any bad gas out so as not to clog your new pump.

[@jasoncrawford4594]

Just out of curiosity can the job still be done if you can't remove the fuel pump relay because currently my fuel pump relay has a wire running from it to the 10 amp horn fuse in order for the fuel pump to work but I am currently needing a new fuel pump so I need to know if the job can still be done with it being like that

[@rawar777joshanderson]

I'm not totally sure (I got rid of the Tucson in 2018) I think it should be fine, especially if you disconnect the battery. There won't be any current running through anything while you're messing around the gas tank.

[@louisleddick7535]

The one you replaced I know about that one under the other seat there's another one but it's round what do you call that one because there's two in them cars because I got one in 05 Hyundai Tucson under the other seat there's a round one under the other seat what's the name of I'm trying to find one they keep showing the other fuel pump but like I said I'm trying to find the other one the round one

[@jehureuveltas1]

Nice video I have all the wires and screws off I just cannot pull up the fuel pump from the tank! Any tips?

[@rawar777joshanderson]

Its starting to get foggy in my mind but at 5:05 , that's how I did it

[@jehureuveltas1]

Josh Anderson Art Thanks for the reply. I’ve been trying to do it the way you mentioned and I still can’t do it it seems impossible but I’ll keep on trying

[@rawar777joshanderson]

Yeah I remember it being stupidly difficult....

[@CaptureYouVideo]

Did you get the thing out ?? Interested to know, because, if you didn't its been 7 months trying. So, how did you go ? I am also a Tucson owner. And, of course, if you completed it , how did it all turn out ? Ta. Shane

[@anthonykenny1120]

Hi, nice video, i replaced my pump on a santafe, simular job,, did the new pump work and solve your issue ?

[@rawar777joshanderson]

Yeah solved that issue but shortly after this the transmission started slipping so I traded it in haha. At that point a new transmission was going to cost about as much as buying a new car that same age.

[@anthonykenny1120]

@@rawar777joshanderson I had the mk1 santafe for 16 years from new, major issues after 12 years but kept it going,, have the mk2 now,,

[@orestis1321]

Nice video friend! Thanks!

[@douglascarducci6977]

Is that basically the same on a 2007 as far as the access under the rear seat?

[@douglascarducci6977]

Nice job pretty sure its the same on a 2007 thanx alot ..though id have to drop tank and all that b.s everyone says

[@rawar777joshanderson]

I don't know about any other years

[@jazzeyjeff953]

thanks. music volume is crazy loud. helpful vid

[@rawar777joshanderson]

Sorry about that haha I've been honing my video editing skills over the years

[@jazzeyjeff953]

@@rawar777joshanderson Timestamps in the description totally made up for it!

[@emjaybennett1496]

You're a genius, thank you sooooo much for this video. Everything I need to know regarding the similar problem I'm experiencing with my own Tucson is so perfectly and clearly explained and demonstrated in this video. Now it's just up to me to do it. Fingers crossed. I don't have a recording system to capture, but I'll definitely give feedback. Cheers!!

[@rawar777joshanderson]

You're welcome!! Apparently every Tucson in the world had this problem judging by the popularity of this video (my most watched video of all time!)

[@emjaybennett1496]

@@rawar777joshanderson My feedback as promised. After watching your video, I went and bought the pump and filter kit and applied exactly what you're showing in the video and it took me less than 40 minutes and the job was done, thanks to you for making this awesome video and sharing your expertise. Now I feel like a genius too. Thank you and God bless you.

[@rawar777joshanderson]

@@emjaybennett1496 SWEET! Thats why I do it!

[@finbarphillip3513]

Hello you have any videos or ideas of how to change a water pump on a Hyundai tuson 2005 diesel engine

[@odhrakabiria2846]

Hola una pregunta tengo la misma camioneta y de un dia para otro no encendió más y al hacer contacto suena igual que la del video y le revisaron los rele y los fucibles pero sigue igual ¿sera la bomba de bencina ?

[@rawar777joshanderson]

I don't speak spanish, but yes it could be the fuel pump.

[@TaintedMojo]

Does the new pump come with it’s own gasket? It’s too bad rock auto doesn’t deliver to my city

[@rawar777joshanderson]

I honestly can't remember. That is a bummer they don't deliver out to you. You must be very rural?

[@TaintedMojo]

@@rawar777joshanderson Naw, we’re between Denver and Boulder. Has something to do with the city collecting online taxes separately from the state......really annoying.

[@Retroprofrank]

Great video man do you have any more work that you've done on that car on your Channel? Keep up the good work!

[@rawar777joshanderson]

Yeah here's the whole playlist:kzbin.info/aero/PL8ouLgcI7hvQTt3e5P9wTjcFx8SLMrNA1 I have a video of doing an oil change on it and one on replacing the alternator

[@Tamcameron]

Hi there, can you advise where is the shredder valve on the Hyundai Tuscon 2007 please

[@rawar777joshanderson]

Sorry, I don't know what a shredder valve is. (Also, I only had the 2005 Tucson)

[@alexmills8812]

Just what i needed, thankyou :)

[@rawar777joshanderson]

Glad to be of some help!

[@maaldiar]

You don't need to pump out the fuel from the tank..i just changed mine today and thought about the reason to pump the fuel out???

[@rawar777joshanderson]

I did this because I saw guys more professional than me in other videos doing it. I believe the reason is that over the years gas leaves deposits and impurities and this may be what caused the pump to fail in the first place and so ideally you wanna get all that out. However, I'm sure it will be fine not doing it too - I'm sure it will be quite a while before that build up affects the new pump.

[@RonnelCuison]

Is the fuel filter and pump in the same assembly?

[@rawar777joshanderson]

I bought them together in the same assembly. But you can buy them separate if you want. It seemed to make more sense to me to go ahead and change both even if one of them was still OK because it is so much trouble.

[@MrMikemary]

I would've syphoned with a hose to a bucket, much faster. but thanks for the vid, i need to change mine.

[@rawar777joshanderson]

Good idea....the pump I used was for pumping out gear oil from a differential....didn't work too well for this

[@YoshsWorld]

Thanks...this is like a replacement I had to do once...but it wasn't a hyundai ...or a tucson....or a fuel pump

[@rawar777joshanderson]

pfff

[@VictorRodriguez-vt1gy]

Thank you

[@albertom.juarez6876]

How much was the fuel pump?

[@rawar777joshanderson]

Gosh I can't even remember now..this was around 4 years ago...I know I ordered it from rockauto.com though

[@nimeni86]

Can i just replace the fuel filter? Where is it?

[@rawar777joshanderson]

You can, but it's inside the fuel pump assembly. You will be taking out the whole assembly either way. I thought of this too to save a little money, but then I thought, with all the trouble of getting that thing out - what if I was wrong and the problem was the pump, not the filter? Then I'd have to do all this over again. So for me I thought I might as well replace the entire assembly...

[@FREEUP2011]

Drive back?

[@rawar777joshanderson]

? Did it drive after this? yep. Until the transmission started slipping haha.

[@windmountain8852]

This repair is expensive and takes time and hassle. How can we be certain the fuel pump is at fault?

[@rawar777joshanderson]

Being totally sure it was the fuel pump is something only a qualified mechanic could tell you. Many times the way I find a problem is by trial and error. Some of the things this car was doing, like sputtering & dying or whatever seemed like it could be vapor lock. So sometimes we'd pull over, take the gas cap off and let it sit for a bit. That seemed to help sometimes but not always. I think what was key here was what I listed at 0:07 in The Problem. The car wasn't firing right up when you turn the key but would if "accessories" were turned on for a second. With the suggestions of some friends, I realized that the pump wasn't delivering fuel efficiently for start up, but turning the key to "accessories" gave the faulty pump a chance to deliver enough fuel to start the car. I could have been wrong, but after doing the job that issue was completely solved proving it had been the problem. Not long after this I had another issue with the car in which a friend and I all but dismantled the engine over 2 weeks and I dropped about $350 in parts into it and when we started it up, the problem was still there! This is the chance you take when doing it DIY. When you factor in shop costs, I figure I saved thousands of dollars doing these things on my own. On the job where we dropped $350 and it wasn't the problem, many things (like the timing belt) needed to be replaced anyway. Time is definitely something you need to factor in. Sometimes those high shop costs are worth it for you not having put up with the hassle...so it's up to you. This fuel pump job really wasn't that expensive and I saved a TON doing it myself! It was a hassle for sure, but that's why I made this video! So the rest of you would have a leg up! Good luck.

[@windmountain8852]

@@rawar777joshanderson Thank you so much for writing this much in details. Your video is very clear and helpful. In case I need to replace fuel pump i am pretty sure I can do it with the help of this video. My 2005 Tucson has only 82000 miles and I think it has something with fuel system. A few months back after i used the 2nd bottle of Chevron fuel injector cleaner (according to mileage it's safe to use one bottle every 1200 mile, I did after 1500 miles), it was cracking but not starting. I pedaled some gas and it started. So I stopped using the fuel inject cleaner. This few day it may be hard to start but cracking. If I gave some gas and pressed the gas pedal fully down and it started with no problem and it started with w a little roar because it had more than enough gas. I will monitor it for a while and did some trial test. Thank you again for the long post explaining the fuel pump.

[@remax281]

man mine is stuck in there i have wiggled it and pulled but something is hanging up

[@rawar777joshanderson]

I really think that is the hardest part of this whole thing.

[@remax281]

@@rawar777joshanderson the top separated from bottom and then I was able to bend tabs to remove

[@micflynn5065]

You need to go side ways and slightly tilt , you are getting caught up on the float.

[@remax281]

@@micflynn5065 it wasnt the flot it was the base of the assembly. the original equipment has some thick tabs that warp outward overtime. its done now thanks

[@lobo5055]

I can’t take out the fuel pump for nothing it’s stuck

[@rawar777joshanderson]

Yeah, not gonna lie it's tricky as hell.

[@wagneroliveira9423]

Estou com minha Tucson sem potencia , talvez seja o filtro e pre filtro

[@alr9170]

I did everything for some reason that sucker doesn't want to come out. I had to pay a mechanic to come to do it

[@rawar777joshanderson]

Thinking back on it, I almost think that was the hardest part of the whole job. I just fanagled it just right...

[@micflynn5065]

You need to pull it out sideways

[@highlightedcomment]

I did all this then discovered my engines timing belt snapped... Piece of crap company not using Kevlar belts. Next vehicles got a gear drive V8

[@ebrahemsweher8438]

ممكن طريقة الفك

[@arkadiuszkijek2141]

A żeś kurwa pomógł