Replace heater hoses on the 2016-2024 Hyundai Tucson 2.5L I4 AWD engine to restore proper coolant flow to the heating system and prevent coolant leaks.

Warnings

Tools required

Parts

• Heater inlet hose × 1 — Use OEM specification
• Heater outlet hose × 1 — Use OEM specification
• Hose clamps × 4 — Worm-gear style, appropriate diameter

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 3 qt

Preparation

1. Ensure engine is completely cold (has not been run for at least 2 hours)
2. Park vehicle on level ground and engage parking brake
3. Place drain pan under radiator drain plug location
4. Remove engine splash shield if equipped to access lower coolant drain

Procedure

1. 1

   Drain cooling system
   Slowly open the radiator cap to release any residual pressure. Locate the coolant drain plug on the bottom of the radiator (driver's side). Position drain pan underneath and remove the drain plug. Allow coolant to drain completely into the pan. Reinstall drain plug and tighten to specification.
   Torque spec

   Coolant Drain Plug15 Nm (11 lb-ft)
2. 2

   Locate heater hoses
   Open the hood and identify the two heater hoses at the firewall, typically on the passenger side. The inlet hose connects from the engine coolant outlet to the heater core, and the outlet hose returns from the heater core to the water pump or coolant return line. Trace hoses from firewall connections to engine connections.
3. 3

   Remove inlet hose clamps
   Using hose clamp pliers or flathead screwdriver, loosen the hose clamps at both ends of the heater inlet hose (at firewall and engine connection point). Slide clamps away from the connection points along the hose. Have shop towels ready to catch residual coolant.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Remove heater inlet hose
   Twist the inlet hose gently to break the seal, then pull firmly to disconnect from both the firewall heater core inlet and the engine-side connection. If hose is stuck due to age, carefully use a flathead screwdriver to pry between hose and fitting while twisting. Remove hose from vehicle and inspect fittings for corrosion or damage.
5. 5

   Remove outlet hose clamps
   Loosen the hose clamps at both ends of the heater outlet hose using the same method as the inlet hose. Slide clamps away from connection points. Position shop towels to catch any remaining coolant.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
6. 6

   Remove heater outlet hose
   Twist and pull the outlet hose to disconnect from the heater core outlet at the firewall and the return connection at the engine (typically at water pump or coolant pipe). Remove hose from vehicle. Check both connection points for damage or excessive corrosion.
7. 7

   Clean connection points
   Use shop towels to clean all four connection points (two at firewall, two at engine). Remove any old coolant residue, corrosion, or debris. Inspect the metal fittings for cracks or damage. The sealing surfaces must be clean and smooth for proper hose seal.
8. 8

   Install new inlet hose
   Slide new hose clamps onto the new heater inlet hose before installation. Route the new inlet hose from the engine connection to the firewall heater core inlet, ensuring proper routing away from hot exhaust components and moving parts. Push hose firmly onto both fittings until it bottoms out against the fitting shoulders.
9. 9

   Secure inlet hose clamps
   Position hose clamps approximately 10mm from the end of each hose connection. Tighten clamps to specification using torque wrench. Ensure clamps are positioned over the hose bead area on the fitting for proper seal.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
10. 10

    Install new outlet hose
    Slide new hose clamps onto the new heater outlet hose. Route the outlet hose from the heater core outlet at the firewall to the engine return connection, maintaining proper clearance from moving parts and heat sources. Push hose fully onto both fittings until seated against the fitting shoulders.
11. 11

    Secure outlet hose clamps
    Position and tighten the outlet hose clamps to specification, ensuring proper placement over the fitting bead area. Verify all four clamps are secure and properly positioned.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
12. 12

    Refill cooling system
    Using a funnel, slowly fill the cooling system with Hyundai/Kia Long Life Coolant (Green) through the radiator cap opening. Fill until coolant reaches the base of the filler neck. Allow coolant to settle and add more as needed. Install radiator cap securely.
13. 13

    Bleed cooling system
    Start the engine and allow it to reach normal operating temperature with the heater set to maximum temperature and fan on high. Monitor coolant level and temperature gauge. As the thermostat opens, coolant level may drop; add coolant as necessary. Run engine for 10-15 minutes to purge air from the system. Check for leaks at all hose connections.

Reassembly

1. Reinstall engine splash shield if it was removed during preparation
2. After engine cools, recheck coolant level and top off to the MAX line on the overflow reservoir
3. Verify all hose clamps are tight and properly positioned

Verification

• With engine cold, inspect all four hose connections for any signs of coolant seepage or wetness
• Start engine and bring to operating temperature; verify heater produces hot air at maximum setting
• Check coolant level in overflow reservoir with engine cold - should be between MIN and MAX marks
• Perform final visual inspection under vehicle for any coolant drips
• Test drive vehicle and monitor temperature gauge to ensure normal operating temperature is maintained

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