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HOMESERVICE MANUALSHYUNDAI2005SANTA FE GLS, 2.7 D, AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 2 (FUEL SYSTEM (G6CU-GSL 3.5))FUEL DELIVERY SYSTEMFUEL TANKREMOVAL
2005 Hyundai Santa Fe GLS, 2.7 D, AWD

Fuel Tank: Removal

2005 Hyundai Santa Fe GLS, 2.7 D, AWDSECTION Removal
WARNING: This page is about a different variant/trim than selected.
  1. 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.
  2. Disconnect the battery cable from the negative terminal of the battery.
    Fig 1: Disconnecting Battery Cable From Negative Terminal Of Battery
    G03845909Courtesy of HYUNDAI MOTOR CO.
  3. Remove the fuel tank cap.
  4. Remove the drain plug and drain the fuel.
  5. Disconnect the return hose and vapor hose.
  6. Disconnect the fuel sender connector.
  7. Disconnect the high pressure hose from the fuel tank.
  8. Loosen the two self-locking nuts, that hold tank in the position and remove the two tank bands.
    Fig 2: Removing Tank Bands
    G03845910Courtesy of HYUNDAI MOTOR CO.
  9. Detach the fuel filler hose and leveling hose.
  10. Remove the fuel vapor hose and the fuel tank.
    Fig 3: Removing Fuel Vapor Hose And Fuel Tank
    G03845911Courtesy of HYUNDAI MOTOR CO.
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.