This procedure removes and replaces the fuel pump module assembly in the fuel tank of a 2016-2024 Hyundai Tucson with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Use OEM Hyundai/Kia part
• Fuel pump lock ring O-ring seal × 1 — Usually included with pump module
• Fuel line quick-connect O-rings × 2 — Use OEM specification

Preparation

1. Ensure fuel tank is less than 1/4 full. If necessary, drain excess fuel using approved fuel transfer equipment
2. Park vehicle on level ground outdoors or in well-ventilated area, engage parking brake, and place wheel chocks
3. Disconnect negative battery cable and wait 3 minutes for system depressurization to begin
4. Remove fuel filler cap to relieve tank pressure
5. Locate fuel pump relay in engine compartment fuse box (refer to fuse box diagram on cover) and remove it
6. Reconnect negative battery cable temporarily, then attempt to start engine. Engine should start briefly then stall as remaining fuel pressure is relieved
7. Attempt to start engine 2-3 more times to ensure all pressure is relieved from fuel lines
8. Disconnect negative battery cable again and keep disconnected for remainder of procedure
9. Remove rear seat cushion by pulling up firmly on front edge to release retaining clips
10. Remove rear seat backrest lower mounting bolts and fold backrest forward for access

Procedure

1. 1

   Access fuel pump module
   Locate the fuel pump access cover in the floor beneath the rear seat (driver side). Use a shop vacuum to clean around the access cover to prevent debris from entering the fuel tank. Remove the access cover screws and carefully lift the cover away. Set aside with fasteners.
   Torque spec

   Access Cover Screws4 Nm (3 lb-ft)
2. 2

   Disconnect electrical connector
   Locate the fuel pump module electrical connector on top of the module. Press the locking tab and carefully disconnect the connector. Inspect connector terminals for corrosion or damage. Clean if necessary with electrical contact cleaner.
   ⚠Do not use excessive force on electrical connectors. Damaged terminals will require harness repair.
3. 3

   Disconnect fuel lines
   The fuel pump module has two quick-connect fuel line fittings: a supply line (larger diameter) and a return line. Using the appropriate fuel line disconnect tool, press the release mechanism and pull the fuel line straight off each fitting. Have a rag ready to catch residual fuel spillage. Inspect the quick-connect fittings and O-rings for damage.
   ⚠Fuel will spill when lines are disconnected. Have drain pan and rags positioned to catch fuel.
   ℹ️Mark or photograph fuel line positions if not clearly labeled to ensure correct reconnection.
4. 4

   Remove fuel pump lock ring
   Install the fuel pump lock ring tool onto the lock ring, ensuring it engages properly in the lock ring notches. Using a breaker bar or long-handled ratchet, rotate the lock ring counterclockwise to loosen. The lock ring requires significant force to break loose. Once loosened, unscrew the lock ring completely by hand and remove it. Set aside with the old O-ring seal.
   ⚠️DO NOT use a hammer and punch to loosen the lock ring as this can create sparks. Use only the proper lock ring tool.
   ⚠Keep face and body clear of fuel tank opening in case of fuel splash during lock ring removal.
   Torque spec

   Fuel Pump Lock Ring68 Nm (50 lb-ft)
5. 5

   Remove fuel pump module
   Carefully lift the fuel pump module straight up and out of the fuel tank. Tilt the module slightly to allow the fuel level sender arm to clear the tank opening. The module will have residual fuel in it. Hold the module over the drain pan and allow fuel to drain completely. Place the old module in a sealed container if it will not be immediately disposed of.
   ⚠The fuel level sender float arm extends from the module and can be damaged if bent. Handle carefully during removal.
   ℹ️Approximately 0.5-1.0 quarts of fuel will drain from the module. Ensure drain pan has adequate capacity.
6. 6

   Inspect fuel tank
   With the module removed, use a flashlight to inspect the interior of the fuel tank for debris, contamination, or sediment. If significant debris is present, the tank should be removed and cleaned before installing the new pump module. Wipe the fuel tank mounting flange clean with a lint-free rag.
   ℹ️Do not allow dirt or debris to enter the fuel tank during inspection.
7. 7

   Prepare new fuel pump module
   Remove the new fuel pump module from its packaging. Verify that the new O-ring seal is properly seated in the groove on the module flange. Check that the fuel level sender float arm moves freely and is not damaged. Lubricate the new O-ring seal lightly with clean gasoline to ease installation.
   ℹ️Verify the replacement module part number matches the original. AWD models may use different modules than 2WD models.
8. 8

   Install new fuel pump module
   Align the fuel pump module with the alignment marks or tabs on the fuel tank flange. The module will only install in one orientation. Carefully lower the module into the tank, tilting as necessary to allow the fuel level sender arm to clear the opening. Once fully seated, rotate the module if necessary to align with fuel line connection positions. Ensure the O-ring seal is properly positioned and not pinched.
   ⚠Do not force the module into position. If resistance is felt, verify the fuel level sender arm is not contacting the tank wall.
9. 9

   Install and torque lock ring
   Place the lock ring over the fuel pump module and thread it onto the tank flange by hand, rotating clockwise. Ensure it threads smoothly without cross-threading. Install the lock ring tool and tighten the lock ring clockwise to the specified torque of 68 Nm (50 lb-ft). Verify the lock ring is fully seated and the module cannot rotate.
   ⚠CRITICAL TORQUE: Under-torquing can cause fuel leaks and fire hazard. Over-torquing can crack the tank flange. Use a torque wrench.
   Torque spec

   Fuel Pump Lock Ring68 Nm (50 lb-ft)
10. 10

    Connect fuel lines
    Install new O-rings on both fuel line quick-connect fittings (supply and return). Lubricate the O-rings lightly with clean gasoline. Push each fuel line straight onto its corresponding fitting on the pump module until a distinct click is heard, indicating the line is locked. Gently pull on each line to verify it is securely connected and will not pull off.
    ⚠CRITICAL CONNECTION: Improperly connected fuel lines can result in fuel leaks, fire, and engine damage. Verify positive engagement of locking mechanism.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
11. 11

    Connect electrical connector
    Reconnect the electrical connector to the fuel pump module. Push firmly until the locking tab clicks into place. Verify the connection is secure by gently pulling on the connector.
    ℹ️Ensure no wires are pinched between the connector and module housing.
12. 12

    Reinstall access cover
    Position the fuel pump access cover over the opening, ensuring any sealing gasket or foam is properly aligned. Install the access cover screws and tighten to 4 Nm (3 lb-ft) in a cross-pattern to ensure even sealing.
    Torque spec

    Access Cover Screws4 Nm (3 lb-ft)
13. 13

    Reinstall rear seat
    Reinstall the rear seat backrest and tighten lower mounting bolts to specification. Reinstall the rear seat cushion by aligning the retaining clips and pressing down firmly until the clips engage.
    ℹ️Verify seat cushion is fully latched on both sides before proceeding.
14. 14

    Restore electrical system
    Reinstall the fuel pump relay in the engine compartment fuse box. Reconnect the negative battery cable and tighten securely. Turn the ignition key to the ON position (without starting) for 2 seconds, then OFF. Repeat this cycle 3-4 times to prime the fuel system and pressurize fuel lines.
    ℹ️You should hear the fuel pump run for approximately 2 seconds each time the ignition is turned ON.

Reassembly

1. Reinstall fuel filler cap securely
2. Remove wheel chocks and verify all tools and parts have been removed from vehicle
3. Dispose of old fuel pump module and contaminated fuel according to local environmental regulations

Verification

• With vehicle still outdoors or in well-ventilated area, start the engine and allow it to idle. Listen for unusual fuel pump noises or rough running
• Inspect the fuel pump access area from inside the vehicle for any fuel odor. Any gasoline smell indicates a leak that must be corrected immediately
• Using a flashlight, inspect around the fuel tank and fuel lines underneath the vehicle for any signs of fuel leakage
• Monitor the fuel gauge to verify it is reading correctly and the fuel level sender is functioning
• Test drive the vehicle and verify normal operation with no hesitation, stalling, or fuel delivery issues
• After test drive, perform a final inspection for fuel leaks at the access cover and all fuel line connections
• If any fuel leaks are detected, immediately shut off engine, disconnect battery, and correct the issue before operating the vehicle

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