This procedure covers the removal and replacement of the high-pressure fuel pump on a 2016-2024 Hyundai Tucson with the 2.5L I4 gasoline engine, including fuel system depressurization and proper torque specifications.

Warnings

Tools required

Parts

• High pressure fuel pump assembly × 1 — Use OEM Hyundai/Kia part
• High pressure fuel pump O-rings × 1 — Usually included with pump
• Fuel line fitting O-rings × 2 — Use OEM specification
• Fuel pump gasket/seal × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground in a well-ventilated area away from ignition sources
2. Ensure engine is completely cold (wait at least 3 hours after last operation)
3. Place fire extinguisher within immediate reach
4. Disconnect negative battery terminal and wait 3 minutes for electrical systems to discharge
5. Remove engine cover by pulling upward on front clips and lifting off
6. Place shop towels and drain pan under fuel pump work area to catch residual fuel

Procedure

1. 1

   Depressurize fuel system
   Locate the fuel pump relay in the engine compartment fuse box (refer to fuse box diagram on lid). Remove the fuel pump relay. Reconnect the battery negative terminal temporarily. Attempt to start the engine - it should start briefly then stall as fuel pressure drops. Crank the engine for 5 additional seconds to ensure complete depressurization. Disconnect the battery negative terminal again. Connect fuel pressure gauge to the fuel rail test port and verify pressure is below 5 psi.
   ⚠️Even after relay removal, residual pressure remains. Always verify with pressure gauge before disconnecting any fuel lines.
2. 2

   Remove air intake components
   Disconnect the mass airflow sensor electrical connector. Loosen the air intake tube clamp at the throttle body. Remove the air filter box mounting bolts and lift the entire air intake assembly from the engine bay. Set aside in a clean area.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Access high pressure fuel pump
   Locate the high-pressure fuel pump on the driver's side of the engine block, below the intake manifold. It is driven by the camshaft and has two fuel line connections (inlet and high-pressure outlet). Remove any cable ties or clips securing wiring near the pump area. Disconnect the fuel pump electrical connector by pressing the release tab.
   ⚠Take photos of fuel line routing and connector positions before removal for proper reassembly reference.
4. 4

   Disconnect fuel supply line
   Using the appropriate fuel line disconnect tool, disconnect the low-pressure fuel supply line from the inlet side of the high-pressure pump. Press the tool onto the fitting and pull the line away from the pump. Have shop towels ready to catch residual fuel (approximately 2-3 tablespoons will drain). Immediately cap or plug the fuel line to prevent contamination.
   ⚠️Wear fuel-resistant gloves and safety glasses. Fuel may spray when disconnecting even after depressurization.
5. 5

   Disconnect high pressure fuel line
   Locate the high-pressure fuel line connection on the outlet side of the pump (typically a metal hardline with a threaded fitting). Using a flare nut wrench or appropriate line wrench, carefully loosen the fuel line fitting. Once loosened, unthread completely and separate the line from the pump. A small amount of fuel may be present. Cap both the line and pump port immediately.
   ⚠️This line operates at extreme pressure during normal operation. Inspect threads carefully for damage. Replace if any damage is visible.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
6. 6

   Remove pump mounting bolts
   Identify the three mounting bolts securing the high-pressure fuel pump to the engine block. Using a socket and extension, remove all three bolts in a crisscross pattern. Keep bolts organized as they may be different lengths. Once bolts are removed, carefully wiggle the pump to break any gasket seal, then pull the pump straight out from the engine block.
   ⚠The pump is driven by a camshaft lobe. Do not rotate the engine with the pump removed, or note camshaft position to ensure proper pump lobe alignment during reinstallation.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
7. 7

   Inspect and clean mounting surface
   Remove and discard the old gasket/O-ring from the engine block mounting surface. Inspect the mounting bore for any debris, metal particles, or damage. Clean the mounting surface thoroughly with a clean, lint-free cloth. Inspect the camshaft drive lobe through the mounting hole - it should show no excessive wear or scoring. Check that no gasket material has fallen into the engine.
   ⚠Do not allow any debris to enter the engine block opening. Cover with a clean lint-free cloth if leaving unattended.
8. 8

   Prepare new high pressure fuel pump
   Unpack the new high-pressure fuel pump and verify all O-rings and seals are included. Install NEW O-rings onto the pump body in the designated grooves. Lightly lubricate the O-rings with clean engine oil (do NOT use petroleum jelly or grease). Verify the pump drive gear/coupling rotates freely by hand. Compare old and new pumps to confirm correct replacement part.
   ⚠Never reuse old O-rings. This will cause high-pressure fuel leaks and potential fire hazard.
9. 9

   Install new fuel pump
   Align the new pump drive coupling with the camshaft lobe inside the mounting bore. The pump will only fit in one rotational position. Carefully push the pump into the mounting bore, ensuring the O-ring does not roll or pinch. Once fully seated, install the three mounting bolts hand-tight, then torque in a crisscross pattern to specification.
   ⚠Ensure pump is fully seated before tightening bolts. Uneven seating will damage O-rings and cause leaks.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
10. 10

    Reconnect high pressure fuel line
    Install a NEW O-ring onto the high-pressure fuel line fitting if equipped with a separate O-ring. Thread the high-pressure line fitting onto the pump outlet by hand until finger-tight. Using a flare nut wrench, tighten the fitting to the specified torque. Double-check that the fitting is properly threaded and seated.
    ⚠️Cross-threading this fitting will cause catastrophic fuel leak under pressure. If resistance is felt, back off and restart threading carefully.
    Torque spec

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

    Reconnect fuel supply line and electrical
    Remove the cap from the low-pressure fuel supply line. Push the fuel line firmly onto the pump inlet until you hear and feel a distinct click, indicating the quick-connect is fully engaged. Tug gently on the line to verify it is locked. Reconnect the fuel pump electrical connector until it clicks into place. Reinstall any cable ties or clips removed earlier.
    ⚠A partially connected quick-connect fitting will leak fuel. Verify the connection is fully locked before proceeding.
12. 12

    Reinstall intake components
    Reinstall the air intake assembly in reverse order of removal. Secure the air filter box with mounting bolts. Connect the intake tube to the throttle body and tighten the clamp to specification. Reconnect the mass airflow sensor electrical connector. Reinstall the engine cover by aligning clips and pressing down until fully seated.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
13. 13

    Pressurize and check for leaks
    Ensure all tools and materials are clear of the engine bay. Reconnect the battery negative terminal. Reinstall the fuel pump relay. Turn the ignition key to the ON position (without starting) for 5 seconds, then OFF. Repeat this cycle 3-4 times to prime the fuel system and build pressure. While the ignition is ON, carefully inspect all fuel connections at the high-pressure pump for any signs of fuel seepage or wetness. Use a flashlight and inspection mirror to check all sides of connections.
    ⚠️Do not start the engine if any fuel leaks are visible. Depressurize system and correct the leak immediately.
14. 14

    Start engine and verify operation
    Start the engine and allow it to idle. Monitor fuel pressure using the fuel rail test port gauge - pressure should stabilize between 1,800-2,200 psi (check service manual for exact specification). Listen for any abnormal noises from the fuel pump area. With engine running, perform a final visual inspection of all fuel connections for leaks. Allow engine to reach operating temperature and verify no leaks develop. Check for diagnostic trouble codes using an OBD-II scanner.
    ⚠️If engine misfires, runs rough, or any fuel smell is detected, shut down immediately and investigate. Do not continue operating vehicle.

Reassembly

1. All components are reassembled during the main procedure steps
2. Ensure all electrical connectors are fully seated with audible clicks
3. Verify all fuel line connections are secure and properly locked
4. Confirm engine cover is properly seated on all mounting clips

Verification

• With engine at operating temperature, verify fuel pressure is within specification (1,800-2,200 psi typical)
• Perform visual inspection of all fuel connections with engine running - no fuel odor or wetness should be present
• Test drive vehicle under various load conditions (acceleration, highway speed, idle) to verify proper fuel delivery
• After test drive, perform cold inspection of all fuel connections for any delayed leaks
• Scan for diagnostic trouble codes - no fuel system codes should be present
• Monitor fuel trim values with scan tool - should be within ±10% at idle and cruise
• Re-inspect all connections after 24 hours and 50 miles of driving

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