2022 Hyundai Tucson Plug-In Hybrid LimitedFACTORY OEM SERVICE PROCEDURE

Repair Procedures: Removal

  1. Release the residual pressure in the fuel line.

    (Refer to Fuel Delivery System - " RELEASE RESIDUAL PRESSURE IN FUEL LINE  ") 

  2. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  3. Remove the air intake hose.

    (Refer to Engine Mechanical System - " AIR CLEANER REPAIR PROCEDURES  ") 

  4. Remove the ECM.

    (Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE (ECM) ")

  5. Separate the fuel feed hose (A) after releasing the fixing clip.
    G16172561Courtesy of HYUNDAI MOTOR AMERICA
  6. Disconnect the engine wiring connector (A).
    G16172562Courtesy of HYUNDAI MOTOR AMERICA
  7. Separate the engine wiring protector (A) after loosening the mounting bolt.

    Tightening torque: 

    7.9 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb.ft)

    G16172563Courtesy of HYUNDAI MOTOR AMERICA
  8. Disconnect the active purge pump connector (A).
  9. Disconnect the camshaft position sensor connector (B).
    G16172564Courtesy of HYUNDAI MOTOR AMERICA
  10. Loosen the engine wiring connector bracket bolt (A).

    Tightening torque: 

    7.9 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb.ft)

    G16172565Courtesy of HYUNDAI MOTOR AMERICA
  11. Loosen the intercooler inlet pipe stay bolt (A).

    Tightening torque: 

    18.7 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.8 - 17.3 lb.ft)

    G16172566Courtesy of HYUNDAI MOTOR AMERICA
  12. Disconnect the intercooler hose (A) after loosening the clamp.
    G16172567Courtesy of HYUNDAI MOTOR AMERICA
    G16172568Courtesy of HYUNDAI MOTOR AMERICA
  13. Remove the intercooler inlet pipe (A).
    G16172569Courtesy of HYUNDAI MOTOR AMERICA
  14. Disconnect the hoses (A) from the active purge pump after releasing the clamps.
    G16172570Courtesy of HYUNDAI MOTOR AMERICA
  15. Remove the active purge pump (A) after loosening the mounting bolts.

    Tightening torque: 

    18.7 - 24.5 N.m (1.9 - 2.5 kgf.m, 13.8 - 18.0 lb.ft)

    G16172571Courtesy of HYUNDAI MOTOR AMERICA
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.