2005 Hyundai XG350 BaseFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Installation

  1. Connect the leveling hose to the tank at approximately 40 mm (1.6 in.) of the filler neck.
  2. When connecting the filler hose, connect the end with the shorter straight pipe to the tank side.
    Fig 1: Connecting Fuel Tank Hoses
    G00721433Courtesy of HYUNDAI MOTOR CO.
  3. 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: Installing Fuel Tank Bands Locking Nuts
    G00721434Courtesy of HYUNDAI MOTOR CO.
  4. Connect the vapor hose and return hose. Attach the fuel hose to the line as shown in the illustration.
    Fig 3: Connecting Fuel Vapor & Return Hoses
    G00721435Courtesy of HYUNDAI MOTOR CO.
  5. 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 torqueΒ 

    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.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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