This procedure covers the removal and replacement of the EVAP purge valve on the 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine. The purge valve controls vapor flow from the charcoal canister to the intake manifold.

Warnings

Tools required

Parts

• EVAP purge valve × 1 — Use OEM specification
• Hose clamps (if damaged) × 2 — Use OEM specification

Preparation

1. Park the vehicle on level ground and engage the parking brake
2. Turn the ignition off and remove the key
3. Allow the engine to cool completely if recently operated
4. Open the hood and secure it in the raised position

Procedure

1. 1

   Locate the EVAP purge valve
   The EVAP purge valve is mounted on the driver's side of the engine bay, near the firewall and above the intake manifold. It is a cylindrical component with two hose connections and an electrical connector. Identify the valve before proceeding with removal.
2. 2

   Disconnect the electrical connector
   Press the locking tab on the electrical connector attached to the EVAP purge valve and pull the connector straight off. Do not pull on the wiring; grip the connector body. Set the connector aside to prevent it from falling into the engine bay.
3. 3

   Disconnect the vapor hoses
   The purge valve has two hoses: one from the intake manifold and one from the EVAP canister. Use a flathead screwdriver or trim tool to carefully release the hose clamps by squeezing or prying them open. Slide the clamps away from the valve connections. Twist and pull each hose straight off the valve nipples. Some fuel vapor odor is normal.
4. 4

   Remove the purge valve mounting bolt
   Using a 10mm socket, remove the single mounting bolt that secures the EVAP purge valve to its bracket on the firewall or engine component. Keep the bolt in a safe location for reinstallation.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Remove the purge valve
   Lift the EVAP purge valve out of its mounting bracket. If the valve is stuck due to heat cycling or residue, gently wiggle it while pulling upward. Inspect the valve for carbon buildup, cracks, or damage. Check the hose nipples for cracks or deterioration.
6. 6

   Inspect hoses and clamps
   Examine both vapor hoses for cracks, deterioration, or soft spots. Check the hose clamps for damage or loss of spring tension. Replace any damaged hoses or clamps. Clean the hose ends with a shop towel if dirt or debris is present.
7. 7

   Install the new purge valve
   Position the new EVAP purge valve into the mounting bracket, ensuring it is oriented the same way as the old valve. The electrical connector should face outward for easy access. Insert the mounting bolt and hand-tighten it initially.
8. 8

   Torque the mounting bolt
   Using a torque wrench, tighten the purge valve mounting bolt to 27.0 Nm (20.0 lb-ft). Ensure the valve sits flush in the bracket and does not rotate during tightening.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Reconnect the vapor hoses
   Push each vapor hose firmly onto the corresponding nipple on the new purge valve until it is fully seated. You should feel the hose bottom out on the nipple. Slide the hose clamps back into position over the connections, approximately 10-15mm from the hose end. Ensure the clamps are tight enough to prevent leaks but not so tight that they damage the hoses.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
10. 10

    Reconnect the electrical connector
    Push the electrical connector onto the purge valve until you hear or feel a distinct click, indicating the locking tab has engaged. Gently tug on the connector to verify it is securely attached and will not come loose during vehicle operation.

Reassembly

1. Verify all hose connections are secure and properly clamped
2. Ensure no tools or parts have been left in the engine bay
3. Double-check that the electrical connector is fully latched

Verification

• Start the engine and allow it to idle; listen for any hissing sounds that might indicate a vacuum leak at the purge valve connections
• Use a scan tool to verify there are no EVAP system fault codes (P0443, P0444, P0445, P0455, P0456) stored in the ECU
• Perform a visual inspection of all connections while the engine is running to confirm no vapor leaks are present
• Test drive the vehicle and monitor for any check engine light illumination or rough idle conditions related to the EVAP system

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