Comprehensive 90,000-mile scheduled maintenance service including fluid changes, filter replacements, spark plugs, and differential services for the 2016-2024 Hyundai Tucson 2.5L I4 AWD.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Use OEM specification
• Engine air filter × 1 — Use OEM specification
• Cabin air filter × 1 — Use OEM specification
• Spark plugs (Iridium) × 4 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Front differential drain plug gasket × 1 — Use OEM specification
• Front differential fill plug gasket × 1 — Use OEM specification
• Rear differential drain plug gasket × 1 — Use OEM specification
• Rear differential fill plug gasket × 1 — Use OEM specification

Fluids

• Hyundai Genuine 0W-20 Engine Oil — 5 qt
• 75W-90 GL-5 Gear Oil — 3.5 qt
• DOT 4 Brake Fluid — 0.5 qt
• Hyundai/Kia Long Life Coolant (Green) — 1 qt

Preparation

1. Park vehicle on level surface and allow engine and drivetrain to cool completely (minimum 2 hours)
2. Gather all fluids, filters, and parts before beginning
3. Raise vehicle on lift or safely support on four jack stands at manufacturer-approved lift points
4. Remove all four wheels and set aside
5. Install magnetic drain pan under engine oil pan

Procedure

1. 1

   Drain engine oil and remove filter
   Locate oil drain plug on bottom of oil pan. Remove drain plug and allow oil to drain completely into pan (approximately 10 minutes). While draining, remove oil filter using filter wrench. Inspect drain plug threads and oil pan threads for damage. Install new crush washer on drain plug and reinstall drain plug.
2. 2

   Install new oil filter and refill engine oil
   Lightly oil the rubber gasket on new oil filter with fresh engine oil. Install new oil filter hand-tight, then an additional 3/4 turn. Do not overtighten. Lower vehicle temporarily and add 5.0 quarts of Hyundai Genuine 0W-20 engine oil through filler cap. Start engine and run for 1 minute, then shut off and check for leaks. Wait 5 minutes, check oil level, and top off to full mark if needed.
3. 3

   Replace engine air filter
   Open hood and locate air filter housing on driver's side of engine bay. Release air box clips and lift cover. Remove old air filter and inspect housing for debris. Clean housing if necessary. Install new air filter ensuring proper seating in housing. Replace cover and secure clips.
4. 4

   Replace cabin air filter
   Locate cabin air filter access panel behind glove box. Remove glove box stops and lower glove box completely. Remove cabin filter cover by pressing release tabs. Slide out old cabin filter, noting airflow direction arrow. Install new filter with airflow arrow pointing in correct direction. Reinstall cover and glove box.
5. 5

   Replace spark plugs
   Remove engine cover if equipped by releasing clips or removing cover screws. Disconnect ignition coil connectors from all four cylinders. Remove coil mounting bolts and carefully pull coils straight up from spark plug wells. Use compressed air to clean debris from around spark plugs. Remove old spark plugs using spark plug socket. Check gap on new plugs (typically 0.039-0.043 inches, verify for your model year). Apply small amount of anti-seize to threads. Install new plugs hand-tight, then torque to specification. Reinstall ignition coils and connectors. Replace engine cover.
   ⚠Do not drop ignition coils or spark plugs. Ceramic insulators can crack and cause misfires.
6. 6

   Drain and refill front differential
   Raise vehicle back onto jack stands. Locate front differential on passenger side of vehicle (integrated with transfer case). Position drain pan under front differential. Remove fill plug first to ensure it's not seized. Remove drain plug and allow gear oil to drain completely (approximately 15 minutes). Install new drain plug gasket and reinstall drain plug to specification. Using fluid transfer pump, add 1.5 quarts of 75W-90 GL-5 gear oil through fill hole until fluid begins to drip out. Install new fill plug gasket and reinstall fill plug.
   ⚠Always remove fill plug before drain plug to avoid being unable to refill if fill plug is seized.
7. 7

   Drain and refill rear differential
   Move drain pan under rear differential located at center of rear axle. Remove fill plug first to verify it's not seized. Remove drain plug and allow gear oil to drain completely (approximately 15 minutes). Inspect magnetic drain plug for excessive metal debris (small amount of fine particles is normal). Clean drain plug thoroughly. Install new drain plug gasket and reinstall drain plug to specification. Using fluid transfer pump, add 2.0 quarts of 75W-90 GL-5 gear oil through fill hole until fluid begins to drip out. Install new fill plug gasket and reinstall fill plug.
   ℹ️Excessive metal chunks on drain plug may indicate differential wear. Consult professional if found.
8. 8

   Inspect and top off brake fluid
   Locate brake fluid reservoir in engine bay near firewall on driver's side. Clean area around cap before opening. Check fluid level and condition. If fluid is dark or contaminated, perform complete brake fluid flush. If fluid is clean and at proper level, top off with fresh DOT 4 brake fluid to MAX line if needed. Do not overfill. Ensure cap is secure.
   ⚠Use only DOT 4 brake fluid. Do not mix different brake fluid types.
9. 9

   Inspect coolant condition and level
   With engine cool, inspect coolant level in overflow reservoir. Level should be between MIN and MAX marks. Check coolant color (should be green). If coolant is rusty or contaminated, schedule complete coolant system flush. If level is low, top off with Hyundai/Kia Long Life Coolant mixed 50/50 with distilled water. Check radiator cap and coolant hoses for cracks or deterioration.
   ⚠️Never open radiator cap or coolant reservoir when engine is hot. Scalding coolant can cause severe burns.
10. 10

    Perform visual drivetrain inspection
    With vehicle raised, visually inspect all CV boots for tears or grease leaks. Check all suspension components for wear or damage. Inspect brake pads and rotors for remaining life. Check exhaust system for leaks or damage. Inspect fuel lines and brake lines for corrosion or damage. Document any issues found for customer review.
11. 11

    Reinstall wheels and lower vehicle
    Clean wheel mounting surfaces on hubs. Install wheels and thread lug nuts by hand. Lower vehicle until wheels just contact ground. Torque lug nuts in star pattern to specification. Fully lower vehicle and remove jack stands.
    ⚠Always torque lug nuts in star pattern to prevent rotor warping.

Reassembly

1. Verify all drain plugs, fill plugs, and filters are properly installed
2. Confirm all engine covers and panels are reinstalled
3. Double-check wheel lug nut torque after lowering vehicle
4. Clean any spilled fluids from under vehicle and engine bay

Verification

• Start engine and verify no oil leaks from filter or drain plug
• Check that oil pressure warning light extinguishes within 3 seconds of starting
• Test drive vehicle for 10-15 minutes, ensuring smooth operation and no warning lights
• Recheck all fluid levels after test drive with engine at operating temperature
• Verify no leaks from differentials or engine
• Reset maintenance reminder light using vehicle settings menu or scan tool

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