This procedure covers removal and replacement of the upper radiator hose on a 2016-2024 Hyundai Tucson with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Upper radiator hose × 1 — Use OEM specification
• Hose clamps (if damaged or corroded) × 2 — Use OEM specification

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 2 qt

Preparation

1. Ensure engine is completely cold to the touch (minimum 2 hours after last operation)
2. Park vehicle on level surface and engage parking brake
3. Open hood and prop securely
4. Locate the radiator drain plug on the lower driver's side of the radiator
5. Place drain pan beneath radiator drain plug

Procedure

1. 1

   Release cooling system pressure
   Slowly rotate the radiator cap counterclockwise to the first detent and allow any residual pressure to escape. Wait until all hissing stops, then remove the cap completely and set aside.
2. 2

   Drain coolant
   Open the radiator drain plug by turning counterclockwise. Allow approximately 2-3 quarts of coolant to drain into the pan until the level drops below the upper hose connection point on the radiator. Close the drain plug finger-tight once draining slows to a drip.
3. 3

   Remove engine cover (if equipped)
   If your Tucson has a plastic engine cover, remove the retaining screws or pull upward on the cover to release the mounting clips. Set aside the cover and any fasteners.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Access upper radiator hose connections
   Locate the upper radiator hose running from the top of the radiator to the thermostat housing on the engine block. Note the orientation of both hose clamps for reinstallation reference.
5. 5

   Loosen radiator-side hose clamp
   Using a flathead screwdriver or hose clamp pliers, loosen the hose clamp at the radiator inlet connection. Slide the clamp back along the hose approximately 2-3 inches away from the radiator neck.
6. 6

   Loosen engine-side hose clamp
   Loosen the hose clamp at the thermostat housing connection on the engine. Slide this clamp back along the hose away from the housing connection point.
7. 7

   Remove upper radiator hose
   Twist the hose gently while pulling to break the seal at both connections. Remove the hose completely. Have shop towels ready as residual coolant will drain from the hose. Inspect both connection points on the radiator and thermostat housing for damage or corrosion.
8. 8

   Prepare new hose
   Compare the new upper radiator hose to the old hose to verify correct length and bend configuration. If reusing hose clamps, slide them onto the new hose in the correct orientation. If using new clamps, position them approximately 1 inch from each hose end.
9. 9

   Install new hose
   Install the new upper radiator hose by pushing firmly onto the radiator inlet neck first, ensuring it seats completely against the neck ridge. Then connect the engine-side end to the thermostat housing, ensuring full seating. The hose should fit snugly without gaps at either connection.
10. 10

    Secure hose clamps
    Position each hose clamp approximately 1/4 inch from the end of each connection point, centered over the hose bead area. Tighten both clamps to specification using a torque wrench. Ensure clamps are positioned beyond the raised bead on each fitting.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
11. 11

    Refill cooling system
    Using a funnel, slowly add Hyundai/Kia Long Life Coolant (Green) to the radiator until it reaches the base of the filler neck. Allow air bubbles to escape as you fill. Add coolant to the coolant reservoir to the MAX line.
12. 12

    Purge air from system
    With the radiator cap still off, start the engine and allow it to idle. Monitor coolant level and add as needed as the thermostat opens and air purges from the system. Run until the upper radiator hose becomes hot to the touch, indicating thermostat opening and proper circulation. Maintain coolant level at the filler neck.
    ⚠Keep hands clear of cooling fan which may engage at any time during this process.
13. 13

    Final fill and seal
    Once engine reaches normal operating temperature and upper hose is hot, shut off engine. Allow to cool for 10 minutes, then top off radiator to the filler neck and reservoir to MAX line. Install radiator cap by pushing down and turning clockwise until it clicks into the locked position.

Reassembly

1. Reinstall engine cover if equipped, ensuring all mounting points are properly seated and screws torqued to specification
2. Wipe down all spilled coolant from engine bay and radiator area
3. Dispose of used coolant according to local environmental regulations

Verification

• Start engine and check for coolant leaks at both upper hose connections while engine warms up
• Verify coolant level remains stable in the reservoir after reaching operating temperature
• Check that heater output is strong, indicating proper coolant circulation
• Inspect hose connections after first drive cycle (50-100 miles) and retighten clamps if seepage is observed
• Monitor coolant level over the next few days and top off reservoir if needed as remaining air purges from system

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