Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSHYUNDAI2003SANTA FE GLS, 2.7 D, FWDREPAIR AND DIAGNOSISENGINE PERFORMANCEENGINE CONTROL SYSTEMSFUEL SYSTEM (2.7L)FUEL DELIVERY SYSTEMFUEL TANKINSTALLATION

2003 Hyundai Santa Fe GLS, 2.7 D, FWD

Fuel Tank: Installation

2003 Hyundai Santa Fe GLS, 2.7 D, FWDSECTION Installation

Connect the leveling hose to the tank and approximately 40 mm (1.6 in.) at the filler neck.
When connecting the filler hose, connect the end with the shorter straight pipe to the tank side.

Fig 1: Identifying Fuel Filler Hose
Courtesy of HYUNDAI MOTOR CO.
Confirm that the pad is fully bonded to the fuel tank. Install the fuel tank by tightening the self-locking nuts to the tank bands until the rear end of the tank band contacts the body.

Fig 2: Identifying Fuel Tank Bands & Self-Locking Nuts
Courtesy of HYUNDAI MOTOR CO.
Connect the vapor hose and return hose. Attach the fuel hose to the line as shown in the illustration.

Fig 3: View Of Fuel Hose
Courtesy of HYUNDAI MOTOR CO.
To connect the high pressure hose to the fuel pump, temporarily tighten the flare nut by hand, and then tighten it to the specified torque. Be careful that the fuel hose does not twist.
Tightening torque

High pressure hose flare nut: 30-40 Nm (300-400 kg.cm, 22-29 lb-ft)

NOTE: When tightening the flare nut, be careful not to bend or twist the line to prevent damage to the fuel pump connection.

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.