This procedure covers removal and replacement of the fuel tank mounting straps on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, including fuel system depressurization and tank lowering.

Warnings

Tools required

Parts

• Fuel tank strap (left) × 1 — Use OEM specification
• Fuel tank strap (right) × 1 — Use OEM specification
• Fuel line O-rings × 1 — Use OEM specification
• Strap mounting hardware kit (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground outdoors or in a well-ventilated area away from any ignition sources
2. Disconnect negative battery cable and wait 3 minutes to prevent fuel pump activation
3. Relieve fuel system pressure by removing fuel pump relay (in engine bay fuse box) and attempting to start engine until it fails to start
4. If tank is more than 1/4 full, siphon fuel using approved fuel transfer pump into approved fuel storage containers
5. Raise vehicle on floor jack and support securely on jack stands at all four corners. Vehicle must be level and stable
6. Remove rear wheels for better access to tank straps and mounting points
7. Allow exhaust system to cool completely if vehicle was recently driven (minimum 1 hour)
8. Place drip pans under fuel tank area to catch any residual fuel spillage

Procedure

1. 1

   Access fuel tank area
   Remove the rear underbody panels and heat shields to access the fuel tank. Remove plastic push clips and fasteners securing the rear underbody cover panels. On AWD models, you may need to remove portions of the exhaust heat shield near the rear differential. Set all hardware aside in labeled containers.
2. 2

   Disconnect fuel filler neck and EVAP lines
   Locate the fuel filler neck hose at the rear driver side of the tank. Loosen the hose clamps using a flathead screwdriver or appropriate tool. Carefully twist and pull the filler neck hose off the tank inlet. Disconnect the EVAP canister vent line and purge line from the top of the tank by pressing the quick-disconnect tabs. Expect some residual fuel spillage into drip pan.
   ⚠Fuel will spill from filler neck hose. Ensure drip pan is positioned properly.
3. 3

   Disconnect electrical connections
   Locate the fuel pump module electrical connector on top of the fuel tank (accessed from underneath). Press the locking tab and carefully disconnect the main fuel pump/fuel level sender connector. On some models, there may be a secondary connector for the fuel pump control module. Disconnect all electrical connections and secure them away from the tank area.
4. 4

   Disconnect fuel supply and return lines
   Locate the fuel supply line (larger diameter) and return line at the front of the fuel tank. Use appropriate fuel line disconnect tools to press the release tabs and disconnect both lines from the fuel pump module. Have drip pan ready as pressurized fuel may still be present despite depressurization. Cap or plug the fuel lines to prevent contamination and further spillage.
   ⚠Even after depressurization, residual pressure may cause fuel to spray. Wear fuel-resistant gloves and eye protection.
5. 5

   Position transmission jack under tank
   Position the hydraulic transmission jack or dedicated fuel tank jack directly under the center of the fuel tank. Raise jack until it just contacts the tank bottom. Place a wide piece of wood or tank saddle on the jack to distribute load evenly. The tank should be supported but not yet bearing full weight. Ensure jack is stable and centered.
   ⚠️Tank must be properly supported before removing straps. Unsupported tank can fall causing severe injury.
6. 6

   Remove rear differential support if necessary
   On AWD models, the rear differential may partially obstruct strap access. If needed, support the rear differential with an additional jack stand and remove or loosen the front differential mounting bolts to allow slight differential movement for clearance. Do not fully remove differential. Only loosen enough to provide access to tank straps.
   ⚠Rear differential must remain supported at all times. Do not allow it to hang from driveshaft or half-shafts.
7. 7

   Remove fuel tank strap mounting bolts
   Locate the two fuel tank straps running across the bottom of the tank from front to rear. Each strap is secured with a bolt at the front and rear ends to the vehicle chassis. Apply penetrating oil to all four strap mounting bolts and wait 5-10 minutes. Using appropriate socket (typically 14mm or 17mm), remove the rear mounting bolt from each strap first. Then remove the front mounting bolts. Support straps as you remove the final bolts to prevent them from falling.
   ⚠Strap mounting bolts may be severely corroded. Apply penetrating oil and use caution to avoid breaking bolts in chassis.
8. 8

   Remove old fuel tank straps
   With all mounting bolts removed and tank supported on jack, carefully pull the straps away from the tank. The straps may be stuck to the tank due to corrosion or undercoating. Use a soft mallet or pry bar to gently separate them. Inspect strap mounting points on chassis for damage or excessive corrosion. Clean mounting surfaces with wire brush.
9. 9

   Inspect tank and clean mounting surfaces
   With straps removed and tank still supported, inspect the fuel tank body for damage, dents, or corrosion, particularly where straps made contact. Clean all strap contact surfaces on tank with wire brush. Inspect tank mounting insulators/cushions and replace if deteriorated. Clean chassis mounting points where strap bolts attach, removing all corrosion and debris.
10. 10

    Install new fuel tank straps
    Position new fuel tank straps over the tank in their mounting locations. Ensure any rubber isolators or cushions are properly positioned between strap and tank. Align strap ends with chassis mounting holes. Start all four mounting bolts by hand to ensure proper thread engagement before tightening any bolt. Straps should route front to rear with any offset or bends matching original orientation.
11. 11

    Torque strap mounting bolts
    Using a torque wrench, tighten all four fuel tank strap mounting bolts to 27 Nm (20 lb-ft) in a cross pattern (front left, rear right, front right, rear left). Verify tank is seated properly in its mounting location and straps are holding it securely without over-compression of rubber isolators. Tank should not move or rattle when pushed gently.
12. 12

    Lower jack and reconnect fuel lines
    Carefully lower the transmission jack slightly to transfer full tank weight to the new straps, but keep jack in place as safety support. Install new O-rings on all fuel line fittings. Reconnect the fuel supply and return lines to the fuel pump module, pressing firmly until you hear/feel a positive click. Tug gently on each line to verify secure connection. Torque any threaded fuel line fittings to 25 Nm (18 lb-ft).
    ⚠Always use new O-rings on fuel line connections. Old O-rings can leak and cause fire hazard.
13. 13

    Reconnect electrical and EVAP connections
    Reconnect the fuel pump module electrical connector, ensuring it clicks securely into place. Reconnect all EVAP lines (vent and purge) to the tank, verifying positive engagement of quick-disconnect fittings. Reconnect fuel filler neck hose to tank inlet and secure with hose clamps torqued to 3 Nm (2 lb-ft). Ensure filler neck is properly seated and aligned.
14. 14

    Reinstall underbody components
    If rear differential was loosened, raise it back to normal position and torque mounting bolts to specification. Reinstall all exhaust heat shields and underbody panels using original hardware. Ensure no fuel lines, EVAP lines, or wiring is pinched or in contact with exhaust components or sharp edges. Reinstall rear wheels and torque lug nuts to specification.
15. 15

    System pressurization and leak check
    Remove jack stands and lower vehicle to ground. Reconnect negative battery cable. Reinstall fuel pump relay. Turn ignition to ON position (do not start engine) for 5 seconds, then OFF for 5 seconds. Repeat this cycle 3-4 times to pressurize fuel system. Immediately inspect all fuel line connections, filler neck, and tank area for any signs of fuel leakage. If any leaks are found, immediately depressurize system and correct the issue before proceeding.
    ⚠️Any fuel leak is a critical safety hazard. Do not start engine or drive vehicle if any leak is detected. Repair immediately.

Reassembly

1. Ensure all fuel line connections are secure with new O-rings installed and properly torqued
2. Verify all electrical connections are fully seated and locked
3. Confirm fuel tank straps are torqued to specification and tank is securely mounted without excessive movement
4. Check that no fuel lines, EVAP lines, or wiring harnesses are pinched, kinked, or in contact with hot exhaust components
5. Verify all underbody panels and heat shields are reinstalled to protect fuel system components from road debris

Verification

• With fuel system pressurized (ignition ON, engine not running), visually inspect all fuel connections for leaks. Look for wet spots, drips, or fuel odor
• Start engine and allow to idle for 5 minutes while monitoring fuel system for leaks. Check tank straps, fuel lines, filler neck, and EVAP connections
• Rev engine gently to 2000-3000 RPM and hold for 10 seconds to increase fuel pressure, then recheck all connections for leaks
• Test drive vehicle in safe area and verify no fuel odor in cabin, no unusual noises from fuel tank area, and no fuel gauge or fuel system warning lights
• After test drive, raise vehicle and perform final inspection of all fuel system components and connections for any signs of leakage or damage
• If any issues are found, immediately cease operation and correct before returning vehicle to service

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