Complete 100,000-mile scheduled maintenance service including fluid changes, filter replacements, spark plugs, and comprehensive inspection for the 2016-2024 Hyundai Tucson 2.5L I4 AWD.

Warnings

Tools required

Parts

• Engine oil filter × 1 — 26300-35503 or equivalent
• Engine air filter × 1 — 28113-D3300 or equivalent
• Cabin air filter × 1 — 97133-D3000 or equivalent
• Spark plugs (Iridium) × 4 — 18855-10080 or NGK equivalent
• Oil drain plug crush washer × 1 — 21513-23001
• Front differential drain plug gasket × 1 — Use OEM specification
• Rear differential drain plug gasket × 1 — Use OEM specification
• Transfer case drain plug gasket × 1 — Use OEM specification

Fluids

• Hyundai Genuine 0W-20 Engine Oil — 5 qt
• 75W-90 GL-5 Gear Oil (Front Differential) — 1.5 qt
• 75W-90 GL-5 Gear Oil (Rear Differential) — 2 qt
• Transfer Case Fluid — 2.5 qt
• Hyundai/Kia Long Life Coolant (Green) — 1 qt
• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow engine to cool completely (minimum 2 hours)
3. Gather all fluids, filters, and parts before beginning
4. Place wheel chocks behind rear wheels
5. Raise front of vehicle with floor jack and support on jack stands at proper jacking points
6. Raise rear of vehicle and support on jack stands
7. Remove all four wheels for access to brakes and differential components
8. Remove engine cover by pulling upward on clip retention points

Procedure

1. 1

   Engine Oil and Filter Change
   Position drain pan under oil drain plug on bottom of oil pan. Remove drain plug and allow oil to drain completely (approximately 10 minutes). Remove old oil filter using filter wrench. Apply thin coat of fresh oil to new filter gasket. Install new filter hand-tight plus 3/4 turn. Clean drain plug area and install new crush washer on drain plug. Install drain plug and torque to specification. Refill engine with 5.0 quarts of 0W-20 oil through filler cap.
2. 2

   Replace Engine Air Filter
   Locate air filter housing on driver's side of engine bay. Release air box clips and remove upper housing section. Remove old air filter element and clean housing interior with damp cloth. Install new air filter ensuring proper seating in housing. Reinstall upper housing and secure clips.
3. 3

   Replace Cabin Air Filter
   Open glove box and remove contents. Press inward on both sides of glove box to release stoppers and lower fully. Remove cabin air filter cover on left side behind glove box. Slide out old cabin air filter noting airflow direction arrow. Install new filter with arrow pointing in correct direction (toward rear of vehicle). Reinstall cover and reset glove box stoppers.
4. 4

   Replace Spark Plugs
   Remove ignition coil connectors by pressing release tab and pulling straight up. Remove four ignition coil mounting bolts. Pull ignition coils straight out of spark plug wells. Use compressed air to clean debris from spark plug wells. Remove spark plugs using spark plug socket. Gap new spark plugs to 0.043 inches (1.1mm). Apply small amount of anti-seize to plug threads (avoid electrode area). Install new plugs hand-tight then torque to 15-20 Nm (11-15 lb-ft). Reinstall ignition coils and connect electrical connectors.
5. 5

   Front Differential Fluid Change
   Locate front differential on passenger side under vehicle. Position drain pan under front differential drain plug. Remove drain plug and allow fluid to drain completely. Clean drain plug and install new gasket. Reinstall drain plug and torque to specification. Locate fill plug on side of differential housing. Remove fill plug and use fluid transfer pump to add 1.5 quarts of 75W-90 GL-5 gear oil until fluid begins to seep from fill hole. Reinstall fill plug.
6. 6

   Rear Differential Fluid Change
   Position drain pan under rear differential drain plug (center of rear axle assembly). Remove drain plug and allow fluid to drain completely. Clean drain plug and install new gasket. Reinstall drain plug and torque to specification. Remove fill plug from side of differential housing. Use fluid transfer pump to add 2.0 quarts of 75W-90 GL-5 gear oil until fluid reaches bottom of fill hole. Reinstall fill plug.
7. 7

   Transfer Case Fluid Change
   Locate transfer case attached to transmission on driver side. Position drain pan under transfer case drain plug. Remove drain plug and allow fluid to drain completely. Clean drain plug and install new gasket. Reinstall drain plug and torque to specification. Remove fill plug from side of transfer case. Use fluid transfer pump to add 2.5 quarts of transfer case fluid until level reaches bottom of fill hole. Reinstall fill plug.
8. 8

   Inspect Brake System and Flush Brake Fluid
   With wheels removed, visually inspect brake pads for wear (minimum 3mm thickness). Check rotors for scoring or excessive wear. Inspect brake lines and hoses for cracks, leaks, or damage. Using brake fluid bleeder kit or assistant, bleed brake system starting with right rear wheel, then left rear, right front, left front. Remove old fluid from master cylinder reservoir and refill with fresh DOT 4 brake fluid. Continue bleeding until fresh fluid (lighter color) appears at each wheel. Maintain reservoir level throughout process.
9. 9

   Inspect Coolant and Top Off
   With engine cold, check coolant level in overflow reservoir. Level should be between MIN and MAX marks. Remove radiator cap and visually inspect coolant condition and level. Test coolant freeze protection using hydrometer (should protect to -35°F minimum). If coolant is clean and level is acceptable, top off as needed with Hyundai/Kia Long Life Green coolant. If coolant is contaminated or low freeze protection, schedule complete coolant system flush.
10. 10

    Comprehensive Undercarriage Inspection
    Inspect all CV axle boots for tears or grease leaks. Check all suspension components for wear, damage, or loose mounting. Inspect exhaust system for leaks, damage, or loose hangers. Check fuel lines and brake lines for corrosion or damage. Inspect drive belts for cracks or glazing (replace if necessary). Check battery terminals for corrosion and tightness. Inspect all fluid levels including transmission and power steering reservoir (if applicable).
11. 11

    Wheel and Tire Service
    Inspect all tires for tread depth (minimum 4/32 inch), uneven wear patterns, sidewall damage, or embedded objects. Check tire pressures and adjust to specification on door jamb placard (typically 33-35 PSI). Rotate tires if needed following recommended pattern. Clean wheel mounting surfaces on hub and wheel. Install wheels ensuring proper seating. Install lug nuts and hand-tighten in star pattern.

Reassembly

1. Torque all wheel lug nuts to 140 Nm (103 lb-ft) in star pattern with wheels still elevated
2. Lower vehicle completely to ground
3. Re-torque all lug nuts to specification in star pattern with vehicle weight on wheels
4. Reinstall engine cover ensuring all clips engage properly
5. Start engine and check for oil leaks around filter and drain plug
6. Check for any fluid leaks from differential and transfer case drain/fill plugs
7. Allow engine to reach operating temperature and verify no coolant leaks

Verification

• Check engine oil level using dipstick - should read between MIN and MAX marks
• Verify no oil, coolant, or differential fluid leaks under vehicle
• Test drive vehicle for 10-15 minutes, monitoring for unusual noises or vibrations
• Check brake pedal feel - should be firm with no excessive travel
• Verify all dashboard warning lights are off after test drive
• Re-check all fluid levels after test drive and top off as necessary
• Reset maintenance reminder in instrument cluster using steering wheel controls
• Document all services performed including mileage and date for maintenance records

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