This procedure covers the replacement of the high-side AC hose on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, including refrigerant recovery, hose removal, installation with new O-rings, and system recharge.

Warnings

Tools required

Parts

• High-side AC hose assembly × 1 — Use OEM Hyundai part specific to 2.5L AWD model
• AC line O-ring set × 1 — Use OEM specification for high-side connections
• PAG 46 oil for AC system × 1 — Use OEM specification

Fluids

• R-134a refrigerant (2016-2019) or R-1234yf (2020-2024)

Preparation

1. Verify the correct replacement hose part number for your specific model year and AWD configuration
2. Ensure AC recovery/recharge equipment is certified and calibrated for your vehicle's refrigerant type (R-134a for 2016-2019, R-1234yf for 2020-2024)
3. Park vehicle on level ground and set parking brake
4. Allow engine to cool completely if recently operated
5. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge
6. Gather new O-rings and PAG oil before beginning disassembly

Procedure

1. 1

   Recover refrigerant from AC system
   Connect AC recovery machine to service ports (low-side on accumulator, high-side near condenser). Follow machine manufacturer's instructions to safely recover all refrigerant from the system. Record the amount of oil recovered for replacement during recharge. Ensure recovery is complete before disconnecting equipment.
2. 2

   Remove engine cover
   Remove the plastic engine cover by pulling upward on the front clips and lifting away. Set aside in a clean area. This provides access to the high-side AC line connections at the compressor.
3. 3

   Locate and access high-side AC hose
   The high-side hose runs from the compressor (passenger side of engine) to the condenser at the front of the vehicle. Identify both connection points. You may need to remove the passenger-side wheel well liner clips for better access to the condenser connection. Use trim tools to avoid breaking clips.
4. 4

   Disconnect hose at compressor
   Using a 17mm flare nut wrench, carefully loosen the high-side line fitting at the compressor discharge port. Hold the compressor port with a backup wrench if needed to prevent turning. Once loose, unthread by hand and carefully remove. Immediately cap the open compressor port to prevent contamination. Remove and discard the old O-rings from the fitting.
5. 5

   Disconnect hose at condenser
   Locate the high-side connection at the condenser inlet (top driver-side of condenser). Use a 14mm flare nut wrench to loosen the fitting. Support the condenser connection to prevent stress. Remove the line and immediately cap the condenser port. Remove and discard old O-rings.
6. 6

   Remove hose routing clips
   The high-side hose is secured to the body and engine with several plastic clips and possibly a metal bracket. Release all clips along the hose routing path. Note the exact routing for proper installation of the new hose. Remove the old hose from the vehicle.
7. 7

   Prepare new hose assembly
   Unpack the new high-side hose. Install new O-rings at both connection points, ensuring they are properly seated in their grooves. Apply a thin coating of clean PAG 46 oil to each O-ring to aid installation and prevent damage. Add approximately 2-3ml of PAG oil into each hose end to replace oil lost during service.
8. 8

   Route new hose
   Route the new high-side hose following the exact path of the original hose. Ensure the hose does not contact any moving parts, sharp edges, or hot surfaces (exhaust manifold). Secure with all original routing clips and brackets. Verify adequate clearance throughout the routing path.
9. 9

   Connect hose to condenser
   Remove the cap from the condenser port. Thread the new hose fitting onto the condenser inlet by hand, ensuring proper alignment and that the O-ring remains in place. Hand-tighten until seated, then use a torque wrench and flare nut wrench to tighten to specification.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Connect hose to compressor
    Remove the cap from the compressor discharge port. Thread the new hose fitting onto the compressor by hand, ensuring the O-ring is properly positioned. Hand-tighten until seated, then torque to specification using a torque wrench and flare nut wrench.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
11. 11

    Evacuate AC system
    Connect evacuation equipment to both service ports. Evacuate the system for a minimum of 45 minutes to remove all air and moisture. Monitor vacuum gauge - system should hold vacuum for at least 10 minutes after pump stops. If vacuum drops, there is a leak that must be located and repaired before proceeding.
12. 12

    Recharge AC system
    Using the recovery/recharge machine, add the correct amount of refrigerant for your model year (consult underhood label for exact capacity, typically 450-550g for 2.5L AWD). Add PAG oil as needed to replace what was recovered in step 1 plus the 5-6ml added to the new hose. Do not overcharge the system.

Reassembly

1. Reinstall passenger-side wheel well liner if removed, ensuring all clips are properly seated
2. Reinstall engine cover, pressing down firmly on all mounting points until clips engage
3. Reconnect negative battery terminal and tighten securely
4. Verify all tools and parts have been removed from engine compartment

Verification

• Start engine and turn AC to maximum cooling with fan on high
• Allow system to run for 5-10 minutes and verify cold air output from vents (should be 38-45°F at vent)
• Inspect both high-side connections at compressor and condenser for any signs of refrigerant leakage (oil residue or frost buildup)
• Use AC leak detector or soap solution to verify no leaks at new connections
• Verify compressor clutch engages and disengages normally when AC is cycled on/off
• Check that high-side pressure reads 200-250 PSI at normal operating temperature (ambient 75-85°F)
• Verify hose does not contact any moving components or hot surfaces during engine operation
• Confirm AC performance meets normal specifications for ambient temperature

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