This procedure replaces the oil pump on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, requiring removal of the timing chain cover and related components.

Warnings

Tools required

Parts

• Oil pump assembly × 1 — Use OEM specification
• Oil pump chain and sprocket kit × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Crankshaft front seal × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• RTV silicone sealant × 1 — Hyundai specified RTV

Fluids

• Hyundai Genuine 0W-20 — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 2 qt

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery cable and secure away from terminal
3. Raise and support vehicle on jack stands at manufacturer lift points
4. Remove engine splash shields and undercovers
5. Drain engine oil completely and remove oil filter
6. Drain coolant from radiator and engine block
7. Remove front bumper cover for access to crankshaft pulley
8. Install engine support fixture across engine bay to support engine weight
9. Position camera or smartphone to photograph timing chain alignment marks before disassembly

Procedure

1. 1

   Remove accessory drive belt and components
   Remove the serpentine belt by releasing tensioner. Remove the alternator and set aside with wiring attached. Remove the A/C compressor mounting bolts and secure compressor to frame without disconnecting refrigerant lines. Remove power steering pump if equipped (this vehicle uses electric steering, verify no mechanical pump is present).
2. 2

   Remove crankshaft pulley
   Lock crankshaft using appropriate holding tool. Remove crankshaft pulley bolt (typically high torque, may require impact wrench). Remove crankshaft pulley using harmonic balancer puller. Do not strike or pry excessively as this can damage the crankshaft.
   ⚠Use only a proper harmonic balancer puller. Prying can damage the crankshaft or pulley.
3. 3

   Support engine and remove motor mount
   Place engine jack with wood block under oil pan to support engine weight. Remove right side engine mount and bracket assembly. Lower engine slightly to gain clearance for timing cover removal. Ensure engine is stable and well-supported throughout procedure.
   ⚠️Verify engine support is secure before removing motor mount. Engine shift can cause injury or component damage.
   Torque spec

   Mounting Bolts47 Nm (35 lb-ft)
4. 4

   Remove timing chain cover
   Disconnect any wiring connectors and hoses attached to timing cover. Remove all timing chain cover bolts in reverse of tightening sequence. Carefully separate timing cover from engine block using plastic pry tool if needed. Remove old gasket material completely. Do not allow debris to enter engine.
   ⚠Use only plastic pry tools on sealing surfaces. Metal tools will damage mating surfaces and cause oil leaks.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
5. 5

   Verify and mark timing chain alignment
   Rotate crankshaft to TDC on cylinder #1 (compression stroke). Verify all timing marks align: crankshaft sprocket mark at 12 o'clock, camshaft sprocket marks aligned with cylinder head surface. Take multiple photos from different angles. Mark chain links adjacent to timing marks with paint pen for reference during reassembly.
   ⚠️Timing alignment is critical. Incorrect timing will cause engine damage upon startup. Verify all marks multiple times.
6. 6

   Remove timing chain tensioner and guides
   Remove timing chain tensioner by pressing locking pin and removing mounting bolts. Remove timing chain guides and tensioner arm. Keep all components organized and labeled for reassembly in correct positions.
   ℹ️Timing chain tensioner cannot be reused if fully extended. Have replacement available if needed.
7. 7

   Remove timing chain and crankshaft sprocket
   Remove timing chain from sprockets. Remove camshaft sprocket bolts and sprockets. Remove crankshaft timing sprocket using appropriate puller if necessary. Do not rotate crankshaft or camshafts from this point forward until reassembly is complete.
8. 8

   Remove oil pan
   Remove all oil pan bolts in a cross pattern starting from outer bolts. Gently tap oil pan with rubber mallet to break gasket seal. Lower oil pan carefully and remove. Clean all gasket surfaces on both oil pan and engine block thoroughly using razor blade scraper. Ensure no debris falls into engine.
   ⚠Cover engine opening with clean shop towels to prevent debris from entering crankcase.
   Torque spec

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

   Remove oil pump pickup tube and oil pump
   Remove oil pump pickup tube mounting bolts and remove tube. Inspect pickup screen for debris or damage. Remove oil pump mounting bolts and oil pump chain tensioner if equipped. Remove old oil pump assembly along with its drive chain and sprockets. Inspect crankshaft drive surface for wear or damage.
   ℹ️Inspect oil pump chain guides and tensioner. Replace if showing wear as these are not always included with oil pump kit.
   Torque spec

   Oil Pump Pickup Tube12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
10. 10

    Install new oil pump assembly
    Clean oil pump mounting surface on engine block thoroughly. Install new oil pump chain onto crankshaft sprocket and oil pump sprocket. Position new oil pump assembly onto engine block, ensuring proper chain alignment and engagement. Install oil pump mounting bolts and tighten to specification in a cross pattern. Verify pump rotates freely by turning crankshaft slightly.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)
11. 11

    Install oil pump pickup tube
    Install new O-ring on oil pump pickup tube. Insert pickup tube into oil pump and position correctly in oil pan area. Install pickup tube mounting bolts and torque to specification. Ensure tube is properly seated and aligned.
    Torque spec

    Oil Pump Pickup Tube12 Nm (9 lb-ft)
12. 12

    Install oil pan with new gasket
    Apply thin bead of RTV sealant to corners where engine block meets timing cover area as specified in service manual. Position new oil pan gasket on engine block. Install oil pan and hand-tighten all bolts. Torque oil pan bolts to specification in a cross pattern starting from center bolts working outward. Allow RTV to cure per manufacturer instructions before adding oil.
    ℹ️Wait minimum 1 hour before filling with oil to allow RTV sealant to cure properly.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
13. 13

    Install timing components and chain
    Install crankshaft timing sprocket with key properly aligned. Install camshaft sprockets loosely. Route timing chain over crankshaft sprocket and camshaft sprockets, aligning all timing marks per factory specifications and your reference photos. Install timing chain guides and tensioner arm. Verify all timing marks are perfectly aligned before proceeding.
    ⚠️Double and triple-check timing alignment. Rotate engine two complete revolutions by hand and verify marks realign exactly. Any misalignment will destroy engine.
14. 14

    Install timing chain tensioner and verify timing
    Compress timing chain tensioner and lock with pin. Install tensioner and torque mounting bolts to specification. Remove tensioner locking pin to apply tension. Slowly rotate crankshaft clockwise two complete revolutions by hand. Verify all timing marks realign perfectly at TDC. If marks do not align, remove chain and repeat timing alignment procedure.
15. 15

    Install timing cover and reassemble front engine components
    Install new crankshaft front seal into timing cover using seal driver. Clean all gasket surfaces thoroughly. Apply new timing cover gasket or RTV sealant as specified by manufacturer. Install timing cover and tighten bolts in proper sequence to specification. Install crankshaft pulley and torque to specification. Reinstall engine mount and remove engine support. Reinstall all accessory components, belts, and shields in reverse order of removal.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Mounting Bolts47 Nm (35 lb-ft)

Reassembly

1. Install new oil drain plug crush washer and torque drain plug to specification
2. Reinstall engine splash shields and undercovers
3. Refill engine with specified 5.0 quarts of Hyundai Genuine 0W-20 oil
4. Install new oil filter and pre-fill with clean oil before installation
5. Refill cooling system with Hyundai/Kia Long Life Coolant to proper level
6. Reconnect negative battery cable
7. Bleed cooling system according to factory procedure

Verification

• Before starting engine, rotate crankshaft by hand two complete revolutions to verify no binding or interference
• Check that crankshaft rotates smoothly with normal resistance throughout rotation
• Start engine and verify oil pressure light extinguishes within 2-3 seconds
• Inspect for oil leaks at oil pan, timing cover, and oil pump area while engine idles
• Allow engine to reach operating temperature and verify no coolant leaks at timing cover
• Check oil level on dipstick after 5 minutes of running and top off if necessary
• Monitor oil pressure gauge or scan tool for proper oil pressure (typically 20-80 PSI depending on RPM and temperature)
• Listen for any abnormal engine noises that could indicate timing or oil pump issues
• Test drive vehicle and verify normal engine operation under load

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