2005 Hyundai XG350 BaseFACTORY OEM SERVICE PROCEDURE

Fuel Tank: Removal

  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 located near the fuel tank.
    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 Negative Cable
    G00721426Courtesy of HYUNDAI MOTOR CO.
  3. Remove the fuel tank cap.
  4. Disconnect the return hose and vapor hose.
    Fig 2: Disconnecting Fuel Return & Vapor Hoses
    G00721427Courtesy of HYUNDAI MOTOR CO.
  5. Disconnect the fuel pump connector.
  6. Disconnect the high pressure hose from the fuel tank.
    Fig 3: Disconnect Fuel High Pressure Hose
    G00721428Courtesy of HYUNDAI MOTOR CO.
  7. Loosen the two self-locking nuts that hold the tank in position and remove the two tank bands.
    Fig 4: Removing Fuel Tank Bands Locking Nuts
    G00721429Courtesy of HYUNDAI MOTOR CO.
  8. Detach the fuel filler hose and leveling hose.
  9. Remove the fuel vapor hose and the fuel tank.
    Fig 5: Removing Fuel Tank Hoses
    G00721430Courtesy of HYUNDAI MOTOR CO.
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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