This procedure covers removal and replacement of the radiator on a 2016-2024 Hyundai Tucson with 2.5L I4 engine and AWD, including coolant drain, hose disconnection, and transmission cooler line removal.

Warnings

Tools required

Parts

• Radiator assembly × 1 — Use OEM specification
• Upper radiator hose × 1 — Inspect and replace if damaged
• Lower radiator hose × 1 — Inspect and replace if damaged
• Radiator drain petcock × 1 — Replace if damaged
• Transmission cooler line O-rings × 2 — Replace during reassembly
• Hose clamps × 4 — Replace spring clamps with worm-drive if desired

Fluids

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

Preparation

1. Ensure engine is completely cold before beginning work
2. Disconnect negative battery terminal to prevent cooling fan activation
3. Raise vehicle on jack stands and remove front undershield/splash guard
4. Place drain pan under radiator drain petcock location
5. Have secondary drain pan ready for transmission cooler line disconnection

Procedure

1. 1

   Drain cooling system
   Open radiator drain petcock at bottom driver side of radiator by turning counterclockwise. Allow coolant to drain completely into drain pan. Remove radiator cap to speed drainage. Once drained, remove drain petcock completely for cleaning or replacement.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
2. 2

   Remove upper engine cover and air intake
   Remove engine cover by pulling upward on retaining clips. Disconnect air intake tube from throttle body and remove air filter housing assembly to gain access to upper radiator area. Disconnect mass airflow sensor electrical connector before removal.
3. 3

   Disconnect upper radiator hose
   Locate upper radiator hose at top driver side of radiator. Use hose clamp pliers or screwdriver to release spring clamp and slide away from radiator neck. Twist hose gently to break seal, then pull hose off radiator inlet. Inspect hose for cracks or deterioration.
   Torque spec

   Upper/Lower Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect lower radiator hose
   From underneath vehicle, locate lower radiator hose connection at bottom passenger side of radiator. Release hose clamp and slide back along hose. Remove hose from radiator outlet. Remaining coolant will drain, ensure drain pan is positioned correctly.
   Torque spec

   Upper/Lower Hose Clamps3 Nm (2 lb-ft)
5. 5

   Disconnect transmission cooler lines
   Locate two transmission cooler lines connected to passenger side of radiator (AWD models have integrated cooler). Position drain pan under connections. Use flare nut wrench to loosen transmission line fittings, turning counterclockwise. Remove lines and plug openings to prevent contamination. Note orientation for reinstallation.
   ⚠Transmission fluid will drain from lines. Approximately 1-2 quarts may be lost and must be replaced.
   Torque spec

   Transmission Cooler Lines25 Nm (18 lb-ft)
6. 6

   Disconnect cooling fan connectors
   Disconnect electrical connectors for cooling fan motor(s). Press release tabs and pull connectors straight back. On AWD models, there are typically two fan motors. Label connectors if needed for reinstallation reference.
7. 7

   Remove radiator mounting bolts and brackets
   Remove upper radiator mounting bolts (typically two 12mm bolts at top corners) securing radiator support brackets. Remove lower mounting bolts or clips at bottom of radiator. Note position of any rubber isolation bushings for reinstallation.
   ⚠Radiator mounting points are plastic and fragile. Support radiator weight during bolt removal.
   Torque spec

   Radiator Mount Bolts12 Nm (9 lb-ft)
8. 8

   Remove radiator assembly
   Carefully lift radiator assembly upward and out of engine bay. Radiator, condenser, and cooling fan assembly typically come out together. Tilt top of radiator toward engine slightly to clear lower mounting points. Have assistant help support assembly as it is awkward and heavy.
   ⚠Do not damage AC condenser fins during removal. Condenser remains attached in front of radiator.
9. 9

   Separate components if needed
   If replacing only radiator, separate cooling fans and condenser from old radiator. Transfer mounting brackets, fan shroud, and rubber bushings to new radiator. Inspect and clean condenser fins. Replace any damaged clips or brackets.
10. 10

    Install new radiator assembly
    Lower new radiator assembly into position, ensuring lower mounting tabs engage properly. Align upper mounting brackets with support frame. Install radiator mount bolts and torque to specification. Ensure rubber isolation bushings are properly seated.
    Torque spec

    Radiator Mount Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect transmission cooler lines
    Install new O-rings on transmission cooler line fittings if applicable. Thread fittings into radiator by hand first to prevent cross-threading. Tighten to specification using flare nut wrench. Verify lines are not kinked or touching sharp edges.
    Torque spec

    Transmission Cooler Lines25 Nm (18 lb-ft)
12. 12

    Reconnect radiator hoses
    Install lower radiator hose onto radiator outlet, ensuring hose is fully seated on neck. Position hose clamp over connection point and tighten to specification. Repeat for upper radiator hose. Verify hoses are routed correctly without kinks or contact with moving parts.
    Torque spec

    Upper/Lower Hose Clamps3 Nm (2 lb-ft)
13. 13

    Reinstall drain petcock and close system
    Clean drain petcock threads and inspect seal. Install petcock into radiator drain hole and hand-tighten only to specified torque. Do not overtighten plastic threads. Reconnect cooling fan electrical connectors.
    Torque spec

    Drain Petcock5 Nm (4 lb-ft)
14. 14

    Refill cooling system
    Fill cooling system with 10 quarts of Hyundai/Kia Long Life Coolant (Green) mixed to proper concentration (typically 50/50 with distilled water). Fill slowly through radiator cap opening. Squeeze upper radiator hose to help purge air. Start engine and allow to reach operating temperature with heater on maximum. Check coolant level and top off as needed. Monitor for leaks.

Reassembly

1. Reinstall front undershield/splash guard
2. Reinstall air intake system and engine cover
3. Reconnect negative battery terminal
4. Check automatic transmission fluid level with engine at operating temperature and add fluid if necessary to compensate for cooler line loss
5. Double-check all hose clamp connections for proper torque and positioning

Verification

• Start engine and verify no coolant leaks from radiator, hoses, or transmission cooler lines
• Allow engine to reach full operating temperature and verify cooling fans activate properly
• Check coolant level in reservoir when engine is cold - should be at FULL COLD mark
• Monitor temperature gauge during test drive to ensure normal operating temperature
• Inspect under vehicle for any fluid drips after test drive
• Verify transmission shifts normally and check fluid level on dipstick (if equipped) or through fill plug

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