This procedure replaces the fuel level sensor located in the fuel tank of a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, requiring removal of the rear seat and fuel pump access cover.

Warnings

Tools required

Parts

• Fuel level sensor × 1 — Use OEM specification
• Fuel pump module O-ring/gasket × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Turn ignition to OFF position and remove key
3. Disconnect negative battery cable and wait at least 2 minutes
4. Relieve fuel system pressure by removing fuel pump fuse and attempting to start engine until it stalls
5. If fuel tank is more than 1/4 full, drain excess fuel using approved fuel transfer equipment
6. Allow exhaust system to cool completely if vehicle was recently driven

Procedure

1. 1

   Remove rear seat cushion
   Pull the rear seat cushion upward firmly at the front edge to disengage the retaining clips. Lift the cushion out of the vehicle to access the fuel pump access panel underneath.
2. 2

   Remove fuel pump access cover
   Locate the plastic access cover in the floor pan beneath where the rear seat was located. Remove the cover screws using a 10mm socket. Carefully lift the cover away to expose the fuel pump module. Clean any debris around the opening to prevent contamination.
   Torque spec

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

   Disconnect fuel pump electrical connector
   Press the locking tab on the fuel pump electrical connector and disconnect it from the fuel pump module. Move the connector aside to prevent damage.
4. 4

   Disconnect fuel lines
   Using the appropriate fuel line disconnect tool, press the tool into the quick-connect fitting on the fuel supply line and pull the line away from the pump module. Repeat for the fuel return line if equipped. Have shop towels ready to catch residual fuel. Cap the lines to prevent contamination.
   ⚠Residual fuel will drain from lines. Have towels ready and immediately wipe up any spills.
5. 5

   Remove fuel pump lock ring
   Using the fuel pump lock ring tool or a brass drift and hammer, rotate the lock ring counterclockwise to unlock it. The ring has directional arrows marked on it. Carefully remove the lock ring and set aside with its O-ring/gasket.
   ⚠Never use steel tools that could create sparks near the fuel tank opening.
6. 6

   Remove fuel pump assembly
   Carefully lift the fuel pump assembly out of the tank at an angle to avoid damaging the fuel level sensor float arm. Tilt the assembly to drain residual fuel back into the tank. Place the assembly in a fuel-safe container. Note the orientation of the assembly for reinstallation.
   ⚠The fuel level sensor float arm extends from the assembly and can be damaged if not removed carefully at an angle.
7. 7

   Remove fuel level sensor from pump assembly
   Locate the fuel level sensor attached to the side of the fuel pump assembly. Disconnect the electrical connector from the sensor. Remove the mounting bracket bolts securing the sensor to the pump housing using a 10mm socket. Carefully slide the sensor and float arm assembly out of the retaining clips.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
8. 8

   Install new fuel level sensor
   Position the new fuel level sensor into the retaining clips on the fuel pump assembly, ensuring the float arm moves freely without binding. Install the mounting bracket bolts and tighten to specification. Reconnect the electrical connector to the sensor, ensuring it clicks into place.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
9. 9

   Install fuel pump assembly
   Install a new fuel pump module O-ring/gasket in the groove on top of the fuel tank opening. Carefully lower the fuel pump assembly into the tank at an angle to clear the float arm, then rotate to the correct orientation as noted during removal. Ensure alignment marks on the pump and tank are aligned.
10. 10

    Install lock ring
    Position the lock ring over the fuel pump module and rotate clockwise using the lock ring tool or brass drift until it locks into place. Verify the lock ring is fully seated and the O-ring is not pinched.
11. 11

    Reconnect fuel lines
    Install new O-rings on the fuel line quick-connect fittings. Push each fuel line firmly onto the corresponding pump module fitting until you hear and feel a click. Pull back on each line to verify it is locked in place.
12. 12

    Reconnect electrical connector
    Reconnect the fuel pump electrical connector to the module, ensuring it clicks securely into place.
13. 13

    Reinstall access cover and seat
    Position the fuel pump access cover over the opening and install the cover screws. Tighten to specification. Reinstall the rear seat cushion by aligning the rear hooks first, then pressing down firmly at the front until the clips engage.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
14. 14

    Reconnect battery and prime fuel system
    Reconnect the negative battery cable. Reinstall the fuel pump fuse. Turn the ignition to ON position (without starting) for 2 seconds, then OFF. Repeat this cycle 3-4 times to prime the fuel system. Inspect all connections for fuel leaks.
    ⚠Check carefully for fuel leaks at all connection points before starting the engine.

Reassembly

1. Ensure all fuel line connections are fully seated and locked before operating vehicle
2. Verify rear seat cushion is fully clipped into place on all retaining points
3. Double-check that no tools or parts were left in the fuel tank area

Verification

• Start the engine and verify it runs normally without fuel starvation or rough running
• Check fuel gauge operation: it should show current fuel level accurately and move smoothly as fuel is added or consumed
• Inspect all fuel connections for leaks with engine running
• Test drive the vehicle and verify fuel gauge responds correctly to vehicle movement and fuel consumption
• Monitor for diagnostic trouble codes related to fuel level sensor circuit

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