Complete removal and replacement of the fuel tank on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, including disconnection of fuel lines, electrical connections, and supporting components.

Warnings

Tools required

Parts

• Fuel tank × 1 — Use OEM specification
• Fuel tank strap set × 1 — Replace if corroded or damaged
• Fuel line O-rings × 4 — Use OEM specification
• Filler neck hose clamp × 1 — Replace if damaged
• Tank shield hardware × 1 — Replace any damaged fasteners

Preparation

1. Ensure fuel tank is nearly empty (less than 1/4 tank). If more than 1/4 tank, use approved fuel transfer pump to remove excess fuel into approved containers.
2. Park vehicle on level surface in well-ventilated area away from ignition sources. Engage parking brake.
3. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge.
4. Raise vehicle on lift or jack stands to provide adequate working clearance underneath. Ensure vehicle is stable and secure.
5. Remove rear wheels to improve access to tank straps and mounting points.
6. Remove plastic underbody panels and heat shields covering fuel tank area using appropriate fasteners.
7. Place large drain pan beneath fuel tank to catch any residual fuel spillage.
8. Have fuel transfer pump or approved fuel storage containers ready if significant fuel remains in tank.

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump fuse in the engine bay fuse box (refer to fuse diagram on cover). Remove the fuel pump fuse. Attempt to start the engine and let it run until it stalls, then crank for an additional 5 seconds to ensure pressure is relieved. Turn ignition off and remove key. This step is critical to prevent fuel spray when disconnecting lines.
   ⚠️Never skip this step. Pressurized fuel lines can spray gasoline several feet when disconnected.
2. 2

   Disconnect fuel filler neck
   Locate the filler neck connection at the rear passenger side of the vehicle. Loosen the filler neck clamp using appropriate tool. Gently twist and pull the filler neck hose from the fuel tank inlet. Be prepared for residual fuel to drain from the hose. If stuck, use plastic mallet to gently tap while twisting.
   ⚠Residual fuel will spill from filler neck. Have drain pan positioned correctly.
   Torque spec

   Filler Neck Clamp4 Nm (3 lb-ft)
3. 3

   Disconnect vapor and vent lines
   Identify the EVAP vapor line and vent lines connected to the top of the fuel tank (typically green and black quick-disconnect fittings). Press the release tabs on each quick-disconnect fitting while pulling the line away from the tank. Mark or photograph connections for correct reinstallation. Cap open lines to prevent contamination.
   ℹ️These are spring-loaded quick-disconnect fittings. Do not force or pry as this will damage the fittings.
4. 4

   Disconnect fuel supply and return lines
   Locate the fuel supply and return line connections at the front of the fuel tank. Using appropriate fuel line disconnect tools, release the quick-disconnect fittings. Allow any residual fuel to drain into pan. Inspect O-rings and fitting condition - these must be replaced during reassembly. Cap or plug open fuel lines immediately to prevent contamination.
   ⚠️Even with pressure relieved, residual fuel will drain. Keep drain pan in place and avoid any ignition sources.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
5. 5

   Disconnect electrical connectors
   Locate the fuel pump module electrical connector on top of the tank (accessible through an access panel or from underneath). Press the release tab and disconnect the connector. Also disconnect any other electrical connections including fuel level sender and tank pressure sensor. Label connections if necessary for reassembly.
   ⚠Ensure battery is disconnected before handling electrical connectors to prevent sparks near fuel vapors.
6. 6

   Remove exhaust heat shield and brackets
   Remove the exhaust heat shield that protects the fuel tank (if equipped) by removing the mounting screws. Remove any support brackets or mounting hardware attached to the tank. Note the position and orientation of all brackets for reinstallation.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)

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

   Support fuel tank
   Position hydraulic transmission jack or equivalent support device directly under the center of the fuel tank. Raise jack until it makes firm contact with the tank bottom. Secure tank to jack using ratchet straps or support chains to prevent the tank from shifting or falling when straps are released. Ensure support is stable and centered.
   ⚠️Tank must be properly supported before removing straps. Even a partially filled tank can weigh over 100 lbs and will fall if not supported.
8. 8

   Remove tank strap bolts
   Locate the two fuel tank strap bolts at the rear of the tank (one on each strap). Using appropriate socket, remove both tank strap bolts completely. The straps will pivot down once bolts are removed. Keep tank supported on jack throughout this process. Inspect straps for corrosion or damage - replace if compromised.
   ⚠️As bolts are removed, tank is held only by jack support. Ensure jack is stable and straps are clear.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
9. 9

   Lower and remove fuel tank
   Slowly lower the hydraulic jack while guiding the tank away from the vehicle underbody. Watch for any remaining connections or interference points. The tank will need to be angled and maneuvered to clear the rear suspension components and exhaust. Once clear of vehicle, carefully lower jack completely and remove tank. Drain any remaining fuel into approved containers.
   ⚠Tank may need to be tilted or rotated to clear suspension and exhaust. Work slowly and have an assistant guide if possible.
10. 10

    Inspect and prepare new tank
    Inspect the mounting area on the vehicle for corrosion, debris, or damage. Clean mounting surfaces with wire brush if needed. Transfer fuel pump module, level sender, and any other components from old tank to new tank if replacing tank (requires separate procedure for pump removal). If reusing tank, clean exterior thoroughly and inspect for damage or corrosion. Install new O-rings on all fuel line fittings - lubricate lightly with clean engine oil.
    ℹ️Never reuse old fuel line O-rings. This is a critical safety component that prevents fuel leaks.
11. 11

    Position and raise tank into place
    Place tank on hydraulic jack and secure with straps. Raise tank into approximate position beneath vehicle. Guide tank into place while watching for clearance with exhaust, suspension, and driveshaft. Align tank mounting points with strap bolt holes. This may require multiple attempts to get proper alignment.
    ⚠Do not force tank into position. Ensure all lines and connections will reach without strain before proceeding.
12. 12

    Install tank straps and bolts
    Swing tank straps up and over the tank into their mounting position. While holding tank in final position with jack, thread both tank strap bolts in by hand. Once both bolts are started, torque to specification in a crossing pattern to ensure even pressure. Verify tank is seated properly against mounting points before final torque.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
13. 13

    Reconnect fuel lines
    Connect fuel supply and return lines to their fittings on the tank. Push firmly until you hear and feel a positive click indicating the quick-disconnect is fully seated. Gently tug on each line to verify secure connection. If using threaded fittings, install with new O-rings and torque to specification. Connect vapor and vent lines in the same manner, ensuring correct routing.
    ⚠️Improperly connected fuel lines will leak under pressure, creating extreme fire hazard. Verify each connection is fully seated.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
14. 14

    Reconnect electrical and filler neck
    Reconnect the fuel pump module electrical connector and any other sensors, ensuring connectors click into place. Route wiring away from heat sources and moving components. Reconnect the filler neck hose to the tank inlet, ensuring it is fully seated. Install new clamp and torque to specification. Verify hose has no kinks or sharp bends.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
15. 15

    Reinstall shields and hardware
    Reinstall exhaust heat shield and any mounting brackets removed earlier. Torque all fasteners to specification. Install underbody panels and wheel well covers. Reinstall rear wheels and torque lug nuts to Hyundai specification (110-130 Nm). Lower vehicle to ground. Remove jack and support stands. Reconnect negative battery terminal.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

    Bracket Bolts20 Nm (15 lb-ft)

Reassembly

1. Ensure all fuel line connections are secure and properly seated - improper connections will leak under pressure
2. Verify all electrical connectors are fully engaged with locking tabs secured
3. Check that fuel tank straps are torqued evenly and tank sits flush against mounting points
4. Confirm filler neck hose is fully seated and clamp is positioned correctly on both hose and tank inlet
5. Verify all heat shields and protective covers are reinstalled to prevent exhaust heat damage
6. Double-check that no tools or parts were left in the tank area before final inspection

Verification

• Reinstall fuel pump fuse. Turn ignition to ON position (do not start) for 2 seconds, then OFF. Repeat 3 times to prime fuel system and build pressure.
• Perform thorough visual inspection of all fuel line connections, filler neck, and tank area for any signs of fuel leakage while system is pressurized.
• Start engine and allow to idle for 5 minutes. Monitor for fuel odors, visible leaks, or warning lights on instrument cluster.
• Rev engine to 2500-3000 RPM several times and recheck all connections for leaks under increased fuel pressure and flow.
• Test fuel gauge reading and verify fuel level sensor is functioning correctly.
• Perform a short test drive, then immediately recheck all connections for any leaks that may appear under vehicle movement and vibration.
• Verify no check engine light or fuel system codes are present using OBD-II scanner.
• If any fuel odor is detected at any point, immediately shut down engine, relieve pressure, and locate and repair leak before operating vehicle.

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