This procedure covers the removal and replacement of the engine oil cooler on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, including coolant drainage, component removal, and system refilling.

Warnings

Tools required

Parts

• Engine oil cooler assembly × 1 — Use OEM specification
• Oil cooler gasket/O-rings × 1 — Typically included with cooler assembly
• Engine oil filter × 1 — 26300-35503 or equivalent
• Coolant drain plug washer × 1 — Use OEM specification
• Lower splash shield clips — As needed for replacement

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 10 qt
• Hyundai Genuine 0W-20 — 5 qt

Preparation

1. Ensure engine is completely cold (at least 2 hours after last operation)
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal to prevent accidental fan operation
4. Raise and support front of vehicle on jack stands at manufacturer lift points
5. Remove engine under cover and front splash shields

Procedure

1. 1

   Drain engine coolant
   Place drain pan under radiator drain plug. Remove radiator cap slowly to release any residual pressure. Open coolant drain plug at the bottom of the radiator and drain coolant completely into pan. Remove and inspect drain plug washer for damage.
   Torque spec

   Coolant Drain Plug15 Nm (11 lb-ft)
2. 2

   Drain engine oil
   Position drain pan under engine oil drain plug. Remove drain plug and allow oil to drain completely. This step is necessary because the oil cooler contains engine oil that will drain during removal. Install drain plug with new washer after draining.
   ℹ️Draining oil now prevents spillage during oil cooler removal and allows for fresh oil during refill.
3. 3

   Remove air intake components
   Disconnect the air intake duct from the throttle body. Loosen clamps and remove air filter housing if necessary to access the oil cooler area. On AWD models, the oil cooler is typically mounted on the front of the engine block near the water pump.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect coolant hoses from oil cooler
   Identify the two coolant hoses connected to the oil cooler (inlet and outlet). Use hose clamp pliers to compress and slide clamps away from connections. Gently twist and pull hoses off the oil cooler fittings. Allow any remaining coolant to drain into pan.
   ⚠Coolant hoses may be stiff. Do not pry against the oil cooler housing as it may crack. Use a pick tool to break the seal if necessary.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
5. 5

   Remove engine oil filter
   Position drain pan under oil filter. Use oil filter wrench to remove the engine oil filter. The oil cooler is integrated with or mounted near the oil filter housing on this engine. Clean the filter mounting surface thoroughly.
   ℹ️The oil filter must be removed to access oil cooler mounting bolts and connections.
6. 6

   Disconnect oil cooler lines
   Locate the engine oil supply and return lines connected to the oil cooler. These are typically metal tubes with threaded fittings or quick-disconnect fittings. Use appropriate wrench to disconnect fittings. Have rags ready to catch residual oil.
   ⚠Use a backup wrench on the oil cooler housing to prevent twisting the cooler body when loosening oil line fittings.
7. 7

   Remove oil cooler mounting bolts
   Locate the mounting bolts securing the oil cooler to the engine block. Typically there are 2-3 bolts holding the cooler assembly. Remove these bolts in a criss-cross pattern to prevent warping. Keep track of bolt locations as they may be different lengths.
   Torque spec

   Housing Bolts14 Nm (10 lb-ft)
8. 8

   Remove oil cooler assembly
   Carefully pull the oil cooler assembly away from the engine block. The cooler may be sealed with O-rings or a gasket that may stick. Gently wiggle the assembly while pulling to break the seal. Do not pry against aluminum surfaces.
   ⚠The oil cooler may still contain residual oil and coolant. Tilt carefully to drain into pan before complete removal.
9. 9

   Clean mounting surfaces
   Thoroughly clean the engine block mounting surface where the oil cooler seals. Remove all old gasket material and O-rings using a plastic scraper. Clean surfaces with brake cleaner and lint-free cloth. Inspect mounting surface for damage or deep scratches that could cause leaks.
   ⚠Do not use metal scrapers on aluminum surfaces. Use only plastic scrapers or gasket removal tools to prevent surface damage.
10. 10

    Install new oil cooler
    Inspect new oil cooler for shipping damage. Install new O-rings or gasket on the new oil cooler (typically included with new unit). Lightly lubricate O-rings with clean engine oil. Align oil cooler with mounting holes and carefully push into place, ensuring gasket seats properly.
    ℹ️Do not reuse old O-rings or gaskets. Always use new seals provided with replacement cooler.
11. 11

    Install and torque mounting bolts
    Install oil cooler mounting bolts and hand-tighten. Torque bolts in a criss-cross pattern to specification. This ensures even pressure on the gasket and prevents warping or leaks.
    ⚠Do not over-torque mounting bolts. Aluminum housings can strip or crack if excessive force is applied.
    Torque spec

    Housing Bolts14 Nm (10 lb-ft)
12. 12

    Reconnect oil lines and coolant hoses
    Reconnect engine oil supply and return lines to the oil cooler, torquing fittings to proper specification. Reconnect coolant inlet and outlet hoses to the oil cooler fittings. Slide hose clamps into position and secure properly.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
13. 13

    Install new oil filter and refill fluids
    Lubricate new oil filter gasket with clean engine oil. Install new oil filter hand-tight plus 3/4 turn. Close radiator drain plug with new washer and torque to specification. Refill cooling system with Hyundai/Kia Long Life Coolant through radiator cap opening. Refill engine with 5 quarts of Hyundai Genuine 0W-20 oil.
    Torque spec

    Coolant Drain Plug15 Nm (11 lb-ft)
14. 14

    Bleed cooling system
    With radiator cap still off, start engine and allow to warm to operating temperature while monitoring coolant level. Add coolant as level drops during bleeding process. Squeeze upper radiator hose to help release air pockets. Run heater on full hot to circulate coolant through heater core. When thermostat opens and coolant circulates, top off to proper level.
    ⚠Monitor engine temperature gauge closely. If temperature rises above normal, shut off engine immediately and investigate for air locks or leaks.

Reassembly

1. Reinstall air intake components and tighten all clamps securely
2. Reinstall engine under cover and splash shields with new clips as needed
3. Lower vehicle from jack stands
4. Reconnect negative battery terminal
5. Allow engine to fully cool, then recheck coolant level in radiator and overflow reservoir

Verification

• Check for oil leaks around oil cooler mounting surface and oil line connections with engine running
• Check for coolant leaks at hose connections and oil cooler sealing surfaces
• Verify engine oil level on dipstick is at proper full mark after running engine
• Verify coolant level is at proper mark in overflow reservoir when engine is cold
• Test drive vehicle and monitor engine temperature gauge for proper operation
• Recheck all connections and fluid levels after test drive and 24 hours of operation
• Monitor for any oil or coolant drips under vehicle during first week of operation

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