This procedure covers the removal and replacement of the lower radiator hose on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, including coolant drainage and refill.

Warnings

Tools required

Parts

• Lower radiator hose × 1 — Use OEM specification
• Hose clamps (if original clamps are damaged) × 2 — Use OEM specification

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 10 qt

Preparation

1. Ensure engine is completely cold (at least 2 hours after last operation)
2. Park vehicle on level surface and engage parking brake
3. Place drain pan under the front of the vehicle
4. Remove engine splash shield if equipped (multiple 8mm bolts)
5. Locate the lower radiator hose connecting the radiator outlet to the lower coolant inlet on the engine block

Procedure

1. 1

   Drain cooling system
   Open the radiator drain petcock located at the bottom driver side of the radiator by turning counterclockwise. Allow coolant to drain completely into the drain pan. If no petcock is present, loosen the lower radiator hose clamp at the radiator end to drain. Collect used coolant for proper disposal.
2. 2

   Remove lower hose clamp at radiator
   Locate the hose clamp securing the lower radiator hose to the radiator outlet (bottom of radiator). Use hose clamp pliers or a flathead screwdriver to compress or loosen the spring clamp. If equipped with a worm-drive clamp, use a flathead screwdriver to loosen completely. Slide the clamp back along the hose away from the radiator connection.
3. 3

   Disconnect hose from radiator
   Twist the lower radiator hose back and forth while pulling to break it free from the radiator outlet pipe. If the hose is stuck due to age, carefully use a flathead screwdriver to gently pry between the hose and radiator fitting. Be careful not to damage the radiator outlet pipe. Remove any residual coolant with shop towels.
4. 4

   Remove lower hose clamp at engine
   Access may be limited on the AWD model. Locate the hose clamp at the engine block coolant inlet (typically on the passenger side of the block). Use hose clamp pliers or flathead screwdriver to loosen or compress the clamp. Slide the clamp back along the hose away from the engine connection point.
5. 5

   Remove lower radiator hose
   Twist and pull the hose to disconnect from the engine block coolant inlet. Fully remove the hose from the vehicle. Inspect both connection points (radiator and engine) for corrosion, debris, or damage. Clean connection surfaces with a shop towel if needed.
6. 6

   Install new lower radiator hose at engine
   Position the new lower radiator hose with the correct orientation (most hoses have a specific routing path). Install the engine end of the hose onto the engine block coolant inlet, pushing firmly until it seats completely against the fitting stop. Ensure the hose is fully inserted (typically 30-40mm onto the fitting).
7. 7

   Secure clamp at engine connection
   Slide the hose clamp into position 10-15mm from the end of the fitting. Position the clamp over the raised bead on the fitting if present. Tighten the clamp to specification using a torque wrench. For spring clamps, ensure they are properly compressed and seated.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
8. 8

   Install hose at radiator
   Route the hose to the lower radiator outlet, ensuring it follows the factory path without kinks or contact with moving parts or hot exhaust components. Push the hose firmly onto the radiator outlet pipe until it seats completely against the stop.
9. 9

   Secure clamp at radiator connection
   Slide the hose clamp into position 10-15mm from the end of the radiator outlet pipe. Position over the raised bead if present. Tighten the clamp to specification using a torque wrench.
   Torque spec

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

    Close drain and refill coolant
    Close the radiator drain petcock by turning clockwise (hand tight only). Remove the radiator cap and fill the radiator with Hyundai/Kia Long Life Coolant (Green) until full. Also fill the coolant reservoir to the MAX line. The system capacity is 10 quarts total.
11. 11

    Bleed cooling system
    Start the engine with the radiator cap off and heater on maximum. Allow the engine to warm up to operating temperature while monitoring coolant level. As the thermostat opens, the coolant level will drop. Add coolant as needed to maintain level. Watch for air bubbles to stop. Rev engine to 2500 RPM several times to help purge air. Once bubbling stops and level stabilizes, install radiator cap securely.
    ⚠Monitor engine temperature gauge during bleeding. If temperature rises above normal, shut off engine immediately and allow to cool.

Reassembly

1. Reinstall engine splash shield if removed, torquing fasteners appropriately
2. Check coolant reservoir level and top off to MAX line if needed
3. Inspect all hose connections for any signs of coolant seepage
4. Wipe down any coolant residue from engine and radiator surfaces

Verification

• Start engine and allow to reach full operating temperature while monitoring for leaks at both hose connections
• Check for proper heater operation by confirming hot air output from climate control system
• Verify coolant level in reservoir remains at MAX line after cool-down
• Inspect ground under vehicle after overnight parking for any coolant drips
• Verify engine temperature gauge reads normal operating temperature (typically middle of gauge)
• Re-check all hose clamps after first drive cycle to confirm proper tightness

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