Fuel Filler Neck

This procedure covers the removal and replacement of the fuel filler neck assembly on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, including disconnection of fuel vapor hoses and mounting hardware.

Warnings

Tools required

Parts

• Fuel filler neck assembly × 1 — Use OEM specification
• Fuel filler neck gasket/seal × 1 — Use OEM specification
• Hose clamps (if damaged) × 2 — Use OEM specification
• Vapor hose clips (replaceable) × 3 — Use OEM specification

Preparation

1. Ensure fuel tank is less than 1/4 full. If necessary, safely drain excess fuel into an approved container
2. Park vehicle on level ground and engage parking brake
3. Slowly remove fuel filler cap to relieve any tank pressure
4. Disconnect negative battery terminal and wait 3 minutes to ensure no ignition sources
5. Raise rear of vehicle and support securely on jack stands at manufacturer-specified lift points
6. Remove left rear wheel for improved access to filler neck area
7. Remove left rear wheel well liner partially by removing forward and center push clips

Procedure

1. 1

   Access fuel door area
   Open the fuel filler door. From inside the cargo area, remove the left rear cargo trim panel by removing the retaining clips. Carefully pull the panel away to expose the back side of the fuel filler neck mounting area.
2. 2

   Remove fuel door assembly
   Remove the two cover screws securing the fuel door hinge assembly to the body. Disconnect the fuel door tether cable if equipped. Set the fuel door assembly aside.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Disconnect vapor hoses
   Locate the EVAP vapor hoses connected to the filler neck assembly (typically 2-3 connections). Using the appropriate disconnect tool, release the quick-connect fittings on each vapor line. Label each connection for reassembly. Use shop towels to catch any residual fuel vapors or condensation.
   ⚠Quick-connect fittings can be damaged if forced. Ensure the disconnect tool is fully engaged before applying pressure.
4. 4

   Loosen hose clamps at tank connection
   From underneath the vehicle, locate where the filler neck connects to the fuel tank inlet. Using a flat-blade screwdriver or socket, loosen the hose clamp securing the filler neck to the tank. Do not fully remove the clamp yet. Be prepared for residual fuel spillage.
   ⚠Position a drain pan beneath the connection point. Fuel will drain from the filler neck when disconnected.
5. 5

   Remove filler neck mounting bolts
   Locate the filler neck mounting bolts securing the assembly to the body (typically 2-3 bolts accessible from the fuel door opening and wheel well area). Remove all mounting bolts using a 10mm socket. Support the filler neck assembly while removing the final bolt.
   Torque spec

   Filler Neck Bolts10 Nm (7 lb-ft)
6. 6

   Remove bracket bolts if present
   Check for any support brackets securing the filler neck along its length (typically one bracket midway down the neck). Remove any bracket bolts using a 12mm socket. Keep hardware organized for reinstallation.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
7. 7

   Separate filler neck from fuel tank
   Carefully twist and pull the filler neck to separate it from the fuel tank inlet. The rubber seal may create resistance. Allow any residual fuel to drain into the catch pan. Maneuver the filler neck assembly out through the wheel well opening or fuel door opening, whichever provides better clearance.
8. 8

   Inspect and clean connection points
   Inspect the fuel tank inlet for damage, cracks, or deformation. Clean the inlet connection area thoroughly with shop towels. Inspect all vapor hose quick-connect fittings for damage. Check the condition of the seal at the tank connection point and replace if worn or damaged.
9. 9

   Prepare new filler neck assembly
   Remove the new filler neck from packaging and verify it matches the original. Install the new gasket/seal onto the end that connects to the fuel tank. Lubricate the seal lightly with clean fuel or soapy water to ease installation. Transfer any brackets or clips from the old assembly if not included with the new part.
10. 10

    Install new filler neck to fuel tank
    Guide the new filler neck assembly into position, routing it through the wheel well or fuel door opening. Align the neck with the fuel tank inlet and push firmly to seat the gasket. Slide the hose clamp into position over the connection and tighten to specification using a torque wrench.
    ⚠Ensure the filler neck is fully seated on the tank inlet before tightening the clamp to prevent fuel leaks.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
11. 11

    Install mounting and bracket bolts
    Position the filler neck assembly against the body mounting points. Install all filler neck mounting bolts finger-tight first to ensure proper alignment. Install any bracket bolts to secure the neck along its length. Torque all filler neck bolts to specification, then torque bracket bolts to specification.
    Torque spec

    Filler Neck Bolts10 Nm (7 lb-ft)

    Bracket Bolts20 Nm (15 lb-ft)
12. 12

    Reconnect vapor hoses
    Reconnect all EVAP vapor hoses to their corresponding fittings on the filler neck assembly, matching your labels from disassembly. Push each quick-connect fitting firmly until it clicks into place. Verify each connection by gently pulling on the line to confirm it is locked.
13. 13

    Reinstall fuel door assembly
    Position the fuel door assembly back into the body opening. Reconnect the tether cable if equipped. Install and torque the cover screws to specification. Verify the fuel door opens and closes smoothly.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Reinstall the left rear cargo trim panel, ensuring all clips are fully seated
2. Reinstall the wheel well liner and secure all push clips
3. Reinstall the left rear wheel and torque lug nuts to manufacturer specification (follow star pattern)
4. Lower vehicle to the ground
5. Reconnect negative battery terminal

Verification

• Add 2-3 gallons of fuel to the tank and monitor the filler neck connection area for leaks
• Start the engine and allow it to idle for 2-3 minutes while continuing to check for fuel leaks
• Perform a visual inspection of all vapor hose connections for proper seating
• Test the fuel door operation to ensure smooth opening and closing
• Check for EVAP system diagnostic trouble codes using an OBD-II scanner. Clear any codes related to fuel system disconnection and verify they do not return after a short test drive
• Perform a 10-15 minute test drive and recheck all connections for leaks afterward

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