This procedure covers removal and replacement of the oil pan on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, including draining oil, removing subframe components for access, and reinstalling with proper sealant and torque specifications.

Warnings

Tools required

Parts

• Oil pan assembly × 1 — 21510-2S000 or equivalent OEM
• Oil pan gasket/sealant × 1 — Hyundai Genuine Silicone Sealant or Three Bond 1217H
• Oil drain plug crush washer × 1 — 21513-23001
• Engine oil filter × 1 — 26300-35503 or equivalent
• Oil pickup tube O-ring × 1 — Use OEM specification

Fluids

• Hyundai Genuine 0W-20 — 5 qt

Preparation

1. Warm engine to operating temperature, then shut off and allow to cool for 30 minutes
2. Raise vehicle on lift or jack stands at all four corners to provide clearance for subframe lowering
3. Remove engine splash shields and front undertray
4. Disconnect negative battery terminal
5. Remove front wheels for access to subframe bolts

Procedure

1. 1

   Drain engine oil and remove filter
   Place drain pan under oil drain plug. Remove drain plug and allow oil to drain completely (approximately 15 minutes). Remove oil filter using filter wrench. Inspect drain plug threads for damage.
2. 2

   Disconnect front exhaust pipe
   Support exhaust system with jack or wire. Remove exhaust pipe-to-manifold nuts and separate connection. Lower exhaust slightly and secure out of work area. Remove oxygen sensor connectors if necessary for clearance.
3. 3

   Support engine and remove engine mounts
   Position transmission jack or engine support bar to hold engine weight. Remove the two front engine mount-to-subframe bolts on both sides. Engine should be supported but not raised at this point.
   ⚠Ensure engine is properly supported before removing mount bolts. Engine must not shift during subframe lowering.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Support and lower front subframe
   Position floor jack under center of front subframe with wood block for even support. Remove four subframe mounting bolts (two per side). Carefully lower subframe approximately 150-200mm (6-8 inches) evenly. Do not allow subframe to hang on brake lines or steering components.
   ⚠️Lower subframe slowly and evenly. Check for any lines, wires, or components that may be under tension as subframe lowers.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Disconnect oil level sensor
   Locate oil level sensor connector on passenger side of oil pan. Depress locking tab and disconnect electrical connector. If equipped, disconnect oil temperature sensor.
6. 6

   Remove oil pan bolts and lower pan
   Remove all oil pan bolts in reverse of tightening sequence (start from outside, work toward center). Note bolt locations as some may be different lengths. Carefully break seal between pan and engine block using plastic pry tool at designated pry points. Lower oil pan while angling past subframe and steering components.
   ⚠Do not pry between sealing surfaces. Use only designated pry points or tap pan gently with rubber mallet to break seal.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)
7. 7

   Remove and inspect oil pickup tube
   Remove bolts securing oil pickup tube to engine block. Carefully extract pickup tube and O-ring from engine. Inspect pickup screen for debris or damage. Clean screen with brake cleaner if reusing.
   Torque spec

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
8. 8

   Clean all sealing surfaces
   Using plastic scraper, remove all old sealant from engine block mating surface and oil pan flange. Follow with razor blade for stubborn residue, being careful not to gouge aluminum surfaces. Clean both surfaces thoroughly with brake cleaner and lint-free cloth. Surfaces must be completely clean, dry, and free of oil.
   ℹ️Any oil, debris, or old sealant remaining on surfaces will cause leaks. Take time to ensure perfect cleanliness.
9. 9

   Install oil pickup tube with new O-ring
   Lubricate new O-ring with clean engine oil. Install O-ring onto pickup tube. Insert pickup tube into engine block, ensuring proper seating. Install and torque pickup tube bolts to specification.
   Torque spec

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
10. 10

    Apply sealant to oil pan
    Apply continuous 2.5-3.0mm bead of Hyundai genuine silicone sealant or equivalent to oil pan sealing surface. Bead should be inside of bolt holes. Pay special attention to corners and curved areas. Sealant must be applied evenly with no gaps. Pan must be installed within 10 minutes of sealant application.
    ⚠Do not apply excessive sealant that can squeeze into oil passages. Use specified bead diameter only.
    ℹ️Once sealant is applied, you have approximately 10 minutes before it begins to cure. Work efficiently.
11. 11

    Install oil pan and torque bolts in sequence
    Carefully position oil pan onto engine block, angling past subframe components. Start all bolts finger-tight. Torque oil pan bolts in sequence from center outward to specified torque. Use multiple passes: first to 6 Nm, then final torque to 12 Nm.
    ⚠Following proper torque sequence is critical to prevent warping and leaks. Do not skip or alter the sequence.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
12. 12

    Reconnect oil level sensor
    Reconnect oil level sensor electrical connector until locking tab clicks into place. Reconnect oil temperature sensor if equipped.
13. 13

    Raise and secure subframe
    Raise subframe evenly using floor jack until mounting holes align with frame. Install all four subframe bolts and torque to specification. Remove support jack.
    ⚠Ensure subframe bolt holes align perfectly before forcing bolts. Misalignment indicates subframe position error.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Reinstall engine mounts
    Install engine mount-to-subframe bolts on both sides. Torque to specification. Remove engine support equipment.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
15. 15

    Reinstall exhaust and install new oil filter
    Reconnect front exhaust pipe to manifold with new gasket if needed. Torque exhaust nuts to specification. Reconnect oxygen sensor connectors. Lubricate new oil filter gasket with clean oil, install filter hand-tight plus 3/4 turn. Install new crush washer on drain plug and torque drain plug to specification.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Allow sealant to cure for minimum 30 minutes before filling with oil
2. Reinstall front wheels and torque lug nuts to specification
3. Install engine splash shields and undertray
4. Reconnect negative battery terminal
5. Fill engine with 5.0 quarts Hyundai Genuine 0W-20 engine oil
6. Reset oil life monitoring system if equipped

Verification

• Start engine and verify oil pressure light extinguishes within 5 seconds
• Allow engine to idle for 2 minutes, monitoring for leaks around oil pan perimeter and drain plug
• Shut off engine, wait 5 minutes, then check oil level and add if necessary to reach full mark
• Road test vehicle and recheck for leaks after 50-100 miles of driving
• Check front wheel alignment and adjust if necessary due to subframe removal

More procedures for this vehicle