This procedure covers the removal and replacement of the evaporative emission system charcoal canister on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Charcoal canister assembly × 1 — Use OEM specification
• Vapor hose clamps × 3 — Replace if damaged
• Mounting hardware × 1 — Replace if corroded

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind front wheels
3. Allow vehicle to sit for at least 30 minutes after last operation to allow fuel vapors to settle
4. Safely raise and support the rear of the vehicle using jack stands
5. Remove driver's side rear wheel for improved access (optional but recommended)

Procedure

1. 1

   Locate charcoal canister
   Position yourself under the vehicle on the driver's side near the rear axle. The charcoal canister is mounted to the chassis rail forward of the rear axle assembly, secured by a bracket. Use a work light to identify the canister and its vapor line connections.
2. 2

   Disconnect vapor line from fuel tank
   Locate the main vapor line running from the fuel tank to the canister. Press the quick-connect fitting release tabs and pull the line straight out from the canister inlet port. If equipped with a hose clamp instead of quick-connect, loosen the clamp and slide it back on the hose before removing.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect purge line to engine
   Locate the purge line that runs from the canister to the engine bay (typically on the top of the canister). Press the quick-connect fitting tabs and disconnect the line. Cap or plug the line end to prevent debris entry.
   ℹ️Mark or photograph line positions before removal to ensure correct reconnection.
4. 4

   Disconnect vent line
   Identify the fresh air vent line connection on the canister (usually marked with a different color fitting). Disconnect by pressing release tabs on the quick-connect fitting. This line typically runs to the filler neck area.
5. 5

   Disconnect electrical connector
   Locate the electrical connector for the canister close valve (CCV) or vent valve on the canister body. Press the locking tab and pull the connector straight off. Ensure the connector remains clean and protected during the procedure.
6. 6

   Remove mounting bracket bolts
   Remove the two or three bolts securing the canister mounting bracket to the chassis rail using a 10mm or 12mm socket. Support the canister with one hand while removing the final bolt to prevent it from falling.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
7. 7

   Remove canister from vehicle
   Carefully lower the canister assembly from its mounting location. Maneuver it past any nearby components such as the exhaust system or rear suspension arms. Note the orientation of the canister for proper installation of the replacement unit.
   ⚠The canister may contain liquid fuel condensate. Keep it upright and have a drain pan ready.
8. 8

   Inspect mounting bracket and lines
   Examine the mounting bracket for damage, rust, or elongated bolt holes. Inspect all vapor line fittings and hoses for cracks, hardening, or deterioration. Check that the chassis mounting points are clean and free of corrosion.
9. 9

   Install new charcoal canister
   Position the new canister in the mounting bracket with the correct orientation (inlet, outlet, and vent ports facing their respective line connections). Lift the assembly into place and align the mounting holes with the chassis rail.
10. 10

    Install mounting bracket bolts
    Install the mounting bracket bolts and hand-tighten. Torque the bolts to specification in a cross pattern to ensure even clamping force and proper alignment of the canister.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
11. 11

    Reconnect electrical connector
    Connect the electrical connector to the canister close valve until it clicks into place. Verify the locking tab is fully engaged by gently pulling on the connector.
12. 12

    Reconnect vapor lines
    Connect the fuel tank vapor line, purge line to engine, and fresh air vent line to their respective ports on the canister. Push each quick-connect fitting straight on until it clicks. Verify each connection by pulling gently on the line. If using hose clamps, position clamps properly and torque to specification.
    ℹ️Ensure each line is connected to the correct port. Incorrect connections will cause evaporative system faults.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)

Reassembly

1. Reinstall driver's side rear wheel if removed and torque lug nuts to specification
2. Lower vehicle from jack stands
3. Remove wheel chocks

Verification

• Start the engine and verify no check engine light appears related to evaporative system codes
• Inspect all vapor line connections under the vehicle for proper seating and no audible hissing
• Perform an EVAP system leak test using a scan tool if available to confirm system integrity
• Drive vehicle for at least one complete drive cycle to allow the ECU to complete EVAP system monitors
• Verify no fuel vapor odor is present around the vehicle during and after refueling

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