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 TANKREMOVAL

2003 Hyundai Santa Fe GLS, 2.7 D, FWD

Fuel Tank: Removal

2003 Hyundai Santa Fe GLS, 2.7 D, FWDSECTION Removal

To reduce the internal pressure of the fuel main pipes and hose, first start the engine and then disconnect the electrical fuel pump connector in the rear seat side.
CAUTION: Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose otherwise fuel will spill out.
Disconnect the battery cable from the negative terminal of the battery.

Fig 1: Disconnecting Negative Battery Cable
Courtesy of HYUNDAI MOTOR CO.
Remove the fuel tank cap.
Remove the drain plug and drain the fuel.
Disconnect the return hose and vapor hose.

Fig 2: Identifying Fuel Return & Vapor Hose
Courtesy of HYUNDAI MOTOR CO.
Disconnect the fuel sender connector.
Disconnect the high pressure hose from the fuel tank.

Fig 3: Identifying High Pressure Hose
Courtesy of HYUNDAI MOTOR CO.
Loosen the two self-locking nuts, that hold tank in the position and remove the two tank bands.

Fig 4: Identifying Fuel Tank Bands & Self-Locking Nuts
Courtesy of HYUNDAI MOTOR CO.
Detach the fuel filler hose and leveling hose.
Remove the fuel vapor hose and the fuel tank.

Fig 5: Identifying Fuel Vapor Hose

Courtesy of HYUNDAI MOTOR CO.

RENDER: 1.0x

NO RELATED

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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.