This procedure covers removal and replacement of the throttle body on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, including disconnection of electrical connectors and air intake components.

Warnings

Tools required

Parts

• Throttle body gasket × 1 — Use OEM specification
• Throttle body assembly × 1 — Use OEM specification if replacing

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect the negative battery terminal and wait 3 minutes for system discharge
3. Remove the engine cover by pulling upward on the four retaining clips
4. Position drain pan or towels below work area in case of residual coolant in throttle body (if equipped with coolant heated type)

Procedure

1. 1

   Disconnect air intake system
   Loosen the air intake hose clamp at the throttle body using a flathead screwdriver or 8mm socket. Carefully pull the intake hose away from the throttle body and secure it out of the way. On some models, you may need to disconnect the breather hose from the air intake tube first.
   Torque spec

   Air Intake Hose Clamps3 Nm (2 lb-ft)
2. 2

   Disconnect throttle body electrical connector
   Locate the electrical connector on the right side of the throttle body. Press the release tab and carefully pull the connector straight off the throttle body. Do not pull on the wires themselves.
   ⚠Ensure connector lock tab is fully depressed before pulling to avoid breaking the connector.
3. 3

   Disconnect coolant hoses if equipped
   If your throttle body has coolant heating (two small hoses connected to the body), use pliers to slide the hose clamps back, then carefully twist and pull the coolant hoses off. Have shop towels ready to catch any coolant spillage. If no coolant hoses are present, skip this step.
   ℹ️Not all 2.5L throttle bodies have coolant heating. Only disconnect if present on your specific model.
4. 4

   Remove throttle body mounting bolts
   Remove the four throttle body mounting bolts using a 10mm socket and extension. Keep track of bolt locations as they may be different lengths. Carefully pull the throttle body away from the intake manifold. The gasket may stick to either surface.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
5. 5

   Remove and inspect old gasket
   Remove the old throttle body gasket from the intake manifold mounting surface. Use a plastic scraper if needed to remove any stuck gasket material. Clean both the intake manifold mating surface and throttle body mating surface with a clean shop towel. Inspect for any damage or deep scratches that could cause air leaks.
   ⚠Do not use metal scrapers on aluminum surfaces as this can cause gouging and vacuum leaks.
6. 6

   Clean or inspect throttle body
   If reusing the throttle body, inspect the throttle plate and bore for carbon buildup. Use only throttle body cleaner spray and a soft cloth to clean the exterior and bore entrance. Do not manually open the throttle plate. If carbon buildup is severe inside the bore, apply cleaner and allow it to soak, then wipe gently. If replacing the throttle body, verify the new unit matches the old one exactly.
   ℹ️Some light carbon buildup is normal and does not always require cleaning if no driveability issues exist.
7. 7

   Install new gasket and position throttle body
   Place the new throttle body gasket onto the intake manifold with the alignment tabs properly positioned. Carefully align the throttle body to the gasket and intake manifold, ensuring the gasket does not shift out of position. Start all four mounting bolts by hand to ensure proper thread engagement.
   ⚠Verify gasket is properly seated on all sides before tightening bolts to prevent vacuum leaks.
8. 8

   Torque throttle body bolts
   Using a torque wrench, tighten the four throttle body mounting bolts in a cross pattern (top left, bottom right, top right, bottom left) to the specified torque of 14 Nm (10 lb-ft). This is a CRITICAL torque specification - do not overtighten as this can warp the throttle body housing or crack the intake manifold.
   ⚠️Overtorquing throttle body bolts can crack the intake manifold or warp the throttle body, causing expensive damage.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
9. 9

   Reconnect coolant hoses if equipped
   If coolant hoses were disconnected in step 3, push them firmly onto the throttle body fittings until fully seated. Slide the hose clamps back into position over the hose ends and verify they are secure. Check coolant level in the reservoir and top off if needed.
10. 10

    Reconnect electrical connector and air intake
    Push the throttle body electrical connector onto the throttle body until it clicks into place. Tug gently to verify it is locked. Reconnect the air intake hose to the throttle body and tighten the hose clamp to 4 Nm (3 lb-ft). Reconnect any breather hoses that were removed.
    Torque spec

    Air Intake Hose Clamps3 Nm (2 lb-ft)

Reassembly

1. Reinstall the engine cover by aligning the clips and pressing down firmly until all four clips snap into place
2. Reconnect the negative battery terminal
3. If coolant hoses were disconnected, verify coolant level is correct and check for leaks around hose connections

Verification

• Start the engine and verify it idles smoothly without hesitation or stalling
• Check for any vacuum leaks around the throttle body gasket by listening for hissing sounds
• Verify there are no check engine lights or fault codes related to the throttle body
• Test drive the vehicle and confirm smooth acceleration with no hesitation or surging
• If coolant hoses were disconnected, recheck for leaks after engine reaches operating temperature
• Some vehicles may require a throttle body relearn procedure - allow the engine to idle for 3-5 minutes, then drive normally for 10-15 minutes to allow the ECU to relearn idle and throttle position

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