This procedure covers removal and replacement of the ABS control module on 2016-2024 Hyundai Tucson 2.5L AWD models, including brake line disconnection, bleeding, and system reprogramming.

Warnings

Tools required

Parts

• ABS control module assembly × 1 — Use OEM specification - requires VIN-specific programming
• Brake line copper crush washers × 6 — OEM brake line sealing washers
• ABS module mounting gasket/seal (if equipped) × 1 — Check OEM parts diagram

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Turn ignition off and disconnect negative battery terminal. Wait 3 minutes for ABS system capacitors to discharge.
3. Open hood and locate brake fluid reservoir. Use turkey baster or fluid pump to remove fluid down to MIN line to minimize spillage during line disconnection.
4. Remove engine cover if equipped by pulling upward on clip fasteners.
5. Locate ABS control module in engine compartment on driver side near firewall, mounted to bracket above brake master cylinder.
6. Take detailed photos of brake line routing and electrical connector orientation for reference during reassembly.
7. Prepare clean workspace with drain pan, rags, and line caps readily accessible.

Procedure

1. 1

   Disconnect ABS module electrical connectors
   Locate the two electrical connectors on the ABS module. Press down on the red secondary lock tab on each connector and slide it toward the wire side. Press the primary lock tab and carefully pull each connector straight off the module. Do not bend pins. Secure connectors away from work area to prevent contamination with brake fluid.
   ⚠Ensure ignition is OFF and battery is disconnected before removing electrical connectors to prevent fault codes or module damage.
2. 2

   Label and disconnect brake lines from ABS module
   The ABS module has six brake line connections (four wheel circuits and two master cylinder feeds). Using masking tape or tags, label each brake line with its position (e.g., LF, RF, LR, RR, MC1, MC2) referencing your photos. Using the appropriate size flare nut wrench (typically 10mm or 12mm), carefully loosen each brake line fitting by turning counterclockwise. Have catch container positioned below to capture fluid. Once loose, unthread fittings by hand and immediately cap open lines and module ports with clean plastic caps to prevent fluid loss and contamination.
   ⚠️Brake fluid will drain from lines and module. Keep catch container positioned to prevent fluid from contacting painted surfaces, wiring, or engine components.
   ⚠Use only flare nut wrenches on brake fittings. Standard wrenches will round off the soft brass fittings, requiring line replacement.
   Torque spec

   Brake Line Fittings15 Nm (11 lb-ft)
3. 3

   Remove ABS module mounting bolts
   The ABS module is secured to its mounting bracket with three bolts. Using appropriate socket (typically 10mm), remove all three ABS module mounting bolts completely. Support the module with one hand while removing the final bolt as the module assembly is heavy (approximately 4-5 lbs). Carefully lift the module straight up and away from the bracket, ensuring no brake lines are still connected.
   Torque spec

   ABS Module Bolts10 Nm (7 lb-ft)
4. 4

   Inspect mounting bracket and brake lines
   With module removed, inspect the mounting bracket for cracks, corrosion, or damage. Clean mounting surface with brake cleaner and lint-free cloth. Examine all six brake line ends for damage, cracks, or flaring issues. Check that copper crush washers are present on each fitting. Replace any damaged lines or washers before proceeding. Verify all rubber brake hoses connected to steel lines show no cracking, bulging, or fluid seepage.
   ⚠Damaged brake lines or fittings must be replaced before installing new module. Do not attempt to reuse damaged components in the brake system.
5. 5

   Prepare new ABS module for installation
   Remove new ABS module from packaging. Verify part number matches old unit and is correct for your vehicle's VIN. Remove all protective caps from module ports. Install new copper crush washers on each of the six brake line fittings (discard old washers). Inspect module mounting surface and install new gasket/seal if equipped. Do not remove any factory shipping plugs from internal ports.
   ℹ️New ABS modules are shipped with internal solenoid valves in closed position. Do not attempt to open valves manually or cycle solenoids before programming.
6. 6

   Install new ABS module to bracket
   Carefully position new ABS module onto mounting bracket, aligning all three bolt holes. Start all three mounting bolts by hand to ensure proper thread engagement. Using torque wrench and working in a star pattern, torque all three mounting bolts to specification. Verify module sits flush against bracket with no gaps.
   ⚠Do not overtighten ABS module bolts. The module housing is aluminum and can crack if excessive torque is applied.
   Torque spec

   ABS Module Bolts10 Nm (7 lb-ft)
7. 7

   Connect brake lines to new module
   Remove caps from brake lines and module ports. Working one line at a time to prevent confusion, thread each brake line fitting into the correct port on the module by hand until snug. Ensure each fitting threads smoothly without resistance (cross-threading will damage the module). Using flare nut wrench, tighten each fitting to specification in the following sequence: master cylinder feeds first, then wheel circuits (LF, RF, LR, RR). Hold module body steady with one hand while tightening to prevent twisting.
   ⚠️Cross-threaded brake fittings will cause brake fluid leaks and system failure. If any fitting does not thread smoothly by hand, stop and inspect for damage or debris.
   Torque spec

   Brake Line Fittings15 Nm (11 lb-ft)
8. 8

   Reconnect electrical connectors
   Clean electrical connector pins with electrical contact cleaner if needed. Align each connector with its corresponding module port and push firmly until primary lock clicks into place. Slide red secondary lock tab back toward connector body until it clicks, securing the connection. Gently tug on each connector to verify it is fully locked. Ensure wiring is routed away from hot engine components and sharp edges.
   ⚠Ensure connectors are fully seated and both lock tabs are engaged. Partial connections will cause ABS system faults.
9. 9

   Refill brake fluid reservoir
   Fill brake fluid reservoir to MAX line with fresh DOT 4 brake fluid from a sealed container. Check reservoir level frequently during bleeding procedure and maintain between MIN and MAX marks. Do not allow reservoir to run dry at any point.
   ⚠Use only fresh DOT 4 brake fluid. Do not reuse old brake fluid or mix different fluid types.
10. 10

    Reconnect battery and perform initial system check
    Reconnect negative battery terminal. Turn ignition to ON position (do not start engine). Verify ABS warning light illuminates for bulb check then remains illuminated (indicating non-programmed module). Check for any immediate fault codes using scan tool. Do not attempt to start engine or cycle ABS until module is programmed.
    ⚠️Do not attempt to drive vehicle or test brakes until module programming and complete system bleeding is finished.
11. 11

    Program and initialize ABS module
    Using OBD-II scan tool with Hyundai ABS programming capability, connect to vehicle DLC port. Follow tool-specific procedures to: 1) Program new module with vehicle VIN, 2) Download current software version, 3) Configure module for AWD and 2.5L specifications, 4) Clear all fault codes, 5) Initialize ABS system sensors. This process typically takes 10-20 minutes. Do not disconnect scan tool or turn off ignition during programming.
    ⚠️Module programming must be completed successfully before bleeding brakes. An unprogrammed module cannot control hydraulic valves and bleeding will be ineffective.
    ℹ️If using aftermarket scan tool, verify it has capability for Hyundai ABS module programming (not just code reading). Incomplete programming will result in non-functional ABS.
12. 12

    Perform automated ABS bleed cycle
    With scan tool still connected, select ABS automated bleeding function. The scan tool will command the ABS module to cycle all solenoid valves in sequence, purging air from the hydraulic unit. During this process, you will hear clicking and motor operation from the ABS module - this is normal. Monitor brake fluid reservoir level constantly and refill as needed. The automated cycle typically runs 2-3 minutes. Once complete, proceed to manual bleeding.
    ⚠Reservoir level will drop significantly during automated bleeding. Check and refill every 30 seconds to prevent air entry.
13. 13

    Bleed brake system at all four wheels
    Bleed brakes in this sequence: Right Rear, Left Rear, Right Front, Left Front. At each wheel: 1) Attach bleeder hose to caliper bleeder screw with clear end submerged in clean brake fluid in catch bottle, 2) Have assistant pump brake pedal 5 times and hold pressure, 3) Open bleeder screw 1/2 turn and observe fluid flow, 4) Close bleeder screw before pedal reaches floor, 5) Repeat until fluid runs clear with no air bubbles (typically 5-10 cycles per wheel), 6) Torque bleeder screw to specification, 7) Check reservoir level and refill as needed. Brake pedal should feel firm when complete.
    ⚠️Never allow brake pedal to go to floor with bleeder screw open or allow reservoir to run dry. Either condition will introduce air requiring complete re-bleeding.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
14. 14

    Verify system operation and check for leaks
    With engine off, pump brake pedal 20-30 times. Pedal should feel firm and consistent with no sponginess. Start engine - pedal may drop slightly (normal with power assist). With vehicle still parked, apply firm brake pressure and inspect all six brake line connections at ABS module for any fluid seepage. Check all wheel bleeder screws for leaks. Wipe all connections dry and recheck after 5 minutes of brake application. Top off reservoir to MAX line.
    ⚠️Any fluid leakage at fittings indicates improper torque or damaged components. Do not drive vehicle until all leaks are corrected.
15. 15

    Perform final diagnostic scan and test drive
    Using scan tool, verify no ABS fault codes are present. Check that all four wheel speed sensors are reading properly (values should show 0 mph with vehicle stationary). Clear any soft codes. Reinstall engine cover if equipped. Test drive vehicle in safe area at low speed (under 20 mph initially), verifying normal brake operation. Gradually increase speed and perform several moderate brake applications. ABS warning light should be OFF. Verify ABS self-test completes (light goes out after 5 seconds). Perform final inspection of all connections for leaks after test drive.
    ⚠️Initial test drive should be in a safe area with no traffic. Be prepared for potential brake issues and leave extra following distance.
    ℹ️ABS may not function properly until vehicle exceeds 12 mph and system completes full initialization. This is normal for new module programming.

Reassembly

1. Torque all fasteners to specified values using calibrated torque wrench - brake system torque specifications are critical for safety.
2. Ensure all electrical connectors have both primary and secondary locks fully engaged.
3. Verify brake fluid level is at MAX line and reservoir cap is securely installed.
4. Reinstall any engine covers, shields, or trim pieces removed for access.
5. Document new ABS module part number and installation date for vehicle service records.

Verification

• Start engine and verify ABS warning light extinguishes after 5 seconds (bulb check complete).
• Check for any active fault codes using scan tool - there should be none related to ABS system.
• Verify brake pedal feels firm with no sponginess when engine is running.
• Inspect all six brake line connections at ABS module - no fluid seepage should be visible.
• Test drive at varying speeds and confirm normal brake operation with no pulsation or fade.
• Verify ABS activates properly by performing controlled stop on loose gravel or wet surface in safe area - should feel pedal pulsation.
• Recheck brake fluid level after test drive and top off if needed - level should remain stable.
• Perform final visual inspection of entire brake system including all four wheels for any leaks or issues.
• If any warning lights remain on, sponginess is present, or leaks are detected, do not drive vehicle - repeat bleeding procedure or seek professional diagnosis.

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