Hyundai Coupes/Sedans 1994-1998 Repair Guide

Fuel Tank

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REMOVAL & INSTALLATION




CAUTION
Take all applicable cautions when working around the fuel tank. Always disconnect the negative battery cable.

  1. Release the fuel system pressure.
  2.  
  3. Leave the fuel pump connector disconnected.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the fuel tank cap.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. Position a suitable drain pan under the fuel tank.
  12.  
  13. Remove the fuel tank drain plug and drain all the fuel from the tank.
  14.  
  15. Label and disconnect the fuel return and vapor hoses from the fuel tank.
  16.  
  17. Label and disconnect the electrical harness from the sending unit.
  18.  
  19. Loosen the flare nut fitting and disconnect the high pressure hose from the fuel tank.
  20.  
  21. Disconnect the fuel filler and leveling hoses from the fuel tank.
  22.  
  23. Loosen the two self-locking nuts that hold the tank bands to the tank.
  24.  
  25. Support the fuel tank from underneath and swing the tank bands down away from the tank.
  26.  
  27. Disconnect the fuel vapor hose
  28.  
  29. Lower and remove the tank.
  30.  

To install:
  1. Raise the fuel tank into position and connect the vapor hose.
  2.  
  3. Make sure the band is bonded fully to the tank and tighten the band until the end of the band contacts the body.
  4.  
  5. Connect the leveling hose to the tank and the filler neck. Make sure the hose is pushed at least 1.6 in. (40mm) onto the filler neck.
  6.  
  7. Connect the filler hose so that the end of the hose with the shorter straight pipe is connected to the tank side.
  8.  
  9. 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.
  10.  
  11. 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. (34-40 Nm).
  12.  

Make sure that the fuel hose does not twist when the flare fitting is being tightened.

  1. Connect the fuel pump and sending unit harnesses.
  2.  
  3. Install the drain plug and tighten to 11-18 ft. lbs. (15-24 Nm).
  4.  
  5. Lower the vehicle.
  6.  
  7. Fill the fuel tank to the proper level.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and allow it to idle.
  12.  
  13. Check for proper fuel pump operation and leaks.
  14.  

 
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