This procedure covers removal and replacement of the fuel pump relay, a common cause of no-start conditions and intermittent fuel delivery issues on the 2016-2024 Hyundai Tucson 2.5L AWD.

Warnings

Tools required

Parts

• Fuel pump relay × 1 — Hyundai 95224-2S000 or equivalent

Preparation

1. Park vehicle on level ground and engage parking brake
2. Turn ignition to OFF position and remove key
3. Allow engine to cool for at least 30 minutes if recently operated
4. Disconnect negative battery terminal using 10mm socket to prevent electrical shorts
5. Wait 2 minutes for residual electrical charge to dissipate
6. Locate the appropriate relay box: For 2016-2019 models, check engine bay relay/fuse box on driver's side. For 2020-2024 models, check both engine bay and interior fuse panel under driver's side dashboard
7. Consult the relay diagram on the underside of the fuse box cover to identify the fuel pump relay position (typically labeled 'FUEL PUMP' or 'F/PUMP')

Procedure

1. 1

   Access relay box
   For engine bay location: Release the fuse box cover clips by pressing tabs and lift cover away. For cabin location: Pull the lower dashboard fuse panel cover by hand to release retaining clips. Set cover aside in clean area to prevent dirt contamination.
2. 2

   Identify fuel pump relay
   Using the relay diagram on the fuse box cover or in owner's manual, locate the fuel pump relay. It is typically a 4-pin or 5-pin micro relay with a 20A or 30A rating. The relay position is usually labeled 'FUEL PUMP', 'F/PUMP', or may be numbered (commonly position 15-25 depending on model year). Verify identification before removal.
3. 3

   Test existing relay (optional but recommended)
   If equipped with a multimeter, test the relay before removal to confirm failure. With battery reconnected temporarily, turn ignition to ON position (do not start). Listen for relay clicking. Use multimeter to check for 12V at relay terminals 85 and 86 (coil side) and continuity between terminals 30 and 87 (contact side) when energized. Document findings. Turn ignition OFF and disconnect battery again.
   ⚠Do not probe relay terminals with metal objects while relay is energized. Use proper multimeter probes only.
4. 4

   Remove fuel pump relay
   Grasp the relay firmly with relay puller or needle-nose pliers. Pull straight upward with steady even pressure to extract relay from socket. Do not rock or twist excessively as this can damage socket terminals. If relay is stuck, gently wiggle side-to-side while pulling upward. Inspect removed relay for burned contacts, melted housing, or corrosion.
5. 5

   Inspect relay socket
   Using flashlight, examine the relay socket for corrosion, burned terminals, bent pins, or debris. Check for green/white corrosion on copper contacts. If corrosion is present, clean contacts with electrical contact cleaner and small wire brush. Ensure all socket terminals are straight and have proper spring tension. If socket shows severe damage or melted plastic, the entire fuse box may require replacement.
   ⚠Never use sandpaper or abrasive materials on relay socket contacts as this removes protective plating and accelerates corrosion.
6. 6

   Install new relay
   Verify the new relay matches the original relay pin configuration and amperage rating (typically 20A or 30A). Orient the relay correctly by aligning the notch or tab on relay body with corresponding feature in socket. Press relay firmly into socket until it seats completely flush with surrounding relays. You should feel a positive click when terminals fully engage. Verify relay cannot be pulled out with light finger pressure.
   ⚠️Installing incorrect relay amperage can cause fuel pump failure or electrical fire. Always verify relay specifications match original equipment.
   Torque spec

   Relay Socket5 Nm (4 lb-ft)
7. 7

   Reconnect battery
   Reconnect negative battery terminal and tighten to specified torque using torque wrench. Ensure connection is clean and secure. Do not overtighten as this can crack battery terminal.
   Torque spec

   Ground Bolt14 Nm (10 lb-ft)
8. 8

   Reinstall covers
   Replace fuse box cover by aligning tabs with slots and pressing firmly until all clips engage with audible clicks. Ensure cover is fully seated and flush. For cabin fuse panel, ensure cover is properly aligned and all retaining clips are engaged.

Reassembly

1. Ensure all fuse box covers are completely seated and latched
2. Verify no tools or parts are left in engine bay or cabin
3. Check that battery connection is tight and corrosion-free

Verification

• Turn ignition to ON position without starting engine. Listen for fuel pump priming (2-3 second buzzing sound from rear of vehicle). This confirms relay is providing power to fuel pump
• If fuel pump does not prime, turn ignition OFF, wait 10 seconds, and try again. Some vehicles require multiple key cycles after battery disconnection
• Start engine and verify it starts normally and runs smoothly at idle for at least 2 minutes
• Turn engine off, wait 30 seconds, and restart to confirm consistent operation
• Check for any warning lights on instrument cluster, particularly check engine light or fuel system warnings
• If equipped with multimeter, verify 12V present at fuel pump relay output terminal (87) when ignition is ON
• Take vehicle for short test drive to confirm no stalling, hesitation, or fuel delivery issues under load
• After test drive, re-inspect relay socket area for any signs of heat, melting, or burning odor which would indicate socket damage or incorrect relay

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