Hyundai Coupes/Sedans 1986-1993 Repair Guide

Fuel Tank

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REMOVAL & INSTALLATION




CAUTION
When working on fuel tanks, be sure to disconnect the battery ground (negative) cable.

1986-89 Excel
  1. Disconnect the negative battery cable. Remove the drain plug and drain the fuel into a suitable waste container.
  2.  
  3. Loosen the fuel hose (main and return) clamps and disconnect the fuel lines.
  4.  
  5. Disconnect the filler hose and breather hose from the filler neck.
  6.  
  7. Remove the fuel tank mounting band while supporting the tank. Lower the fuel tank slightly and disconnect the fuel gauge wiring connector.
  8.  
  9. Remove the fuel tank.
  10.  

To install:
  1. Raise the fuel tank into position and connect the fuel level gauge connector. Make sure the band is bonded fully to the tank and tighten the band until the end touches the ground. Torque the strap nuts to 14 ft. lbs.
  2.  
  3. Connect the breather and filler hoses to the filler neck.
  4.  
  5. Connect the fuel lines to their respective tank connections.
  6.  
  7. Install and tighten the drain plug to 58-72 ft. lbs. (78-98 Nm).
  8.  
  9. Fill the tank to the proper level and connect the negative battery cable.
  10.  

1990-93 Excel, Elantra And Scoupe

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Fuel tank components-1990-93 Excel, Elantra and Scoupe

  1. Release the fuel system pressure as described earlier in this section. Leave the fuel pump connector disconnected.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel tank cap.
  6.  
  7. Raise the rear of the vehicle and support safely.
  8.  
  9. Position a suitable drain pan under the fuel tank. Remove the drain plug and drain all the fuel from the tank.
  10.  
  11. Disconnect the fuel return and vapor hoses from the fuel tank. Make sure that you label which is which.
  12.  
  13. Disconnect the electrical connector from the fuel sending unit.
  14.  
  15. Loosen the flare nut fitting and disconnect the high pressure hose from the fuel tank.
  16.  
  17. Disconnect the fuel filler and leveling hoses from the fuel tank.
  18.  
  19. Loosen the two self-locking nuts that hold the tank bands to the tank. Support the fuel tank from underneath and swing the tank bands down away from the tank. Disconnect the fuel vapor hose, lower and remove the tank.
  20.  

To install:
  1. Raise the fuel tank into position and connect the vapor hose. Make sure the band is bonded fully to the tank and tighten the band until the end of the band contacts the body.
  2.  
  3. Connect the leveling hose to the tank and the filler neck. Make sure the hose is pushed at least 40mm (1.6 in.) onto the filler neck.
  4.  
  5. Connect the filler hose so that the end of the hose with the shorter straight pipe is connected to the tank side.
  6.  
  7. Connect the fuel vapor and return hoses. Make sure the hoses are pushed at least 1.0-1.2 in. (25-30mm) onto their connections.
  8.  
  9. Loosen connect the high pressure hose to the tank by making the flare nut hand tight. Hold the stationary nut with a wrench and torque the flare nut to 23-30 ft. lbs. Make sure that the fuel hose does not twist when the flare fitting is being tightened.
  10.  
  11. Connect the fuel pump and sending unit wires.
  12.  
  13. Install the drain plug and tighten to 11-18 ft. lbs.
  14.  
  15. Lower the vehicle.
  16.  
  17. Fill the tank to the proper level and connect the negative battery cable.
  18.  

Sonata

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Fuel tank components-Sonata

  1. Relieve the pressure from the fuel system.
  2.  
  3. Disconnect the negative battery cable and raise the rear of the vehicle.
  4.  
  5. Remove the fuel tank cap.
  6.  
  7. Remove the drain plug and drain the fuel into a suitable waste container.
  8.  
  9. Label and disconnect the fuel return and vapor hoses.
  10.  
  11. Disconnect the fuel gauge and fuel pump connectors.
  12.  
  13. Disconnect the fuel tank high pressure hose by loosening the union fitting while holding the other fitting stationary.
  14.  
  15. Label and disconnect the fuel filler and leveling hoses from the filler neck.
  16.  
  17. Support the fuel tank from the bottom.
  18.  
  19. Loosen and remove the two self-locking nuts that hold the tank bands in place.
  20.  
  21. Swing the two tank bands down, disconnect the vapor hose and lower the fuel tank to the ground to remove it. After removal, make sure the pad is fully bonded to the tank.
  22.  

To install:
  1. Raise the fuel tank into position and lift the two tank bands into place. Install the tank band self-locking nuts and torque them to 11-18 ft. lbs. until the rear end of the tank makes contact with the body.
  2.  
  3. Push the leveling hose onto the tank so that the hose covers 1.6 in. (40mm) of the connection.
  4.  
  5. Connect the filler hose so that the end having the shorter straight pipe attaches to the tank side.
  6.  
  7. Connect the vapor and return hoses making sure that the hose covers 1.0-1.2 in. (25-30mm) of each connection.
  8.  
  9. Connect the high pressure hose fitting to the fuel pump hose and make hand tight. Hold the other fitting with an open end wrench and torque the fuel tank high pressure fitting to 22-29 ft. lbs.
  10.  

When tightening the high pressure fitting, make sure that the hose is not allowed to become twisted or bent.

  1. Connect the fuel pump and fuel gauge connectors.
  2.  
  3. Install and torque the drain plug to 11-18 ft. lbs. Fill the fuel tank to the proper level.
  4.  

 
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