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Autopapyrus · Hyundai Tucson 1.6 GDI (2015)
https://autopapyrus.com/guides/hyundai/tucson/fuel-filter-replacement-in-the-fuel-pump-module/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Hyundai Tucson 1.6 GDI (2015): Fuel Filter Replacement in the Fuel Pump Module

The third-generation Tucson with the 1.6 GDI gasoline engine has no separate inline fuel filter under the floor. The fine filter is built into the fuel pump module inside the tank. The recommended service interval is about 60,000 km, or sooner if you often fill up at questionable gas stations. The exact procedure for disassembling the module on this model is not documented in publicly available service materials. Below is the general principle, so confirm the details against the manufacturer's service manual.

Difficulty: Hard Time: 2-3 hours Steps: 15

Parts

3
  • 🔩 Fuel filter (strainer and filter element) as part of the fuel pump module
  • 🔩 if heavily worn or the float is sticking, a complete fuel pump module (a separate item, not the same as the filter)
  • 🔩 fuel pump module O-ring

Tools

8
  • Socket set and ratchet
  • screwdrivers
  • plastic trim removal tools
  • special wrench or brass drift for the plastic fuel pump lock ring
  • plastic zip ties
  • container and rags for fuel
  • fire extinguisher
  • gloves and safety glasses
There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes AutoFix (online) and 2 more. See manuals →

Step by step

15 steps
  1. Work outdoors or in a well-ventilated area, away from open flames and sparks. Ideally, the tank should have less than a quarter of fuel.
  2. Disconnect the negative battery terminal. Before doing so, make sure you have the radio code if one is required.
  3. Relieve the fuel system pressure. Remove the fuel pump fuse or relay in the interior or under-hood fuse box, start the engine and wait for it to stall. Then crank the engine with the starter for 2-3 seconds.
  4. Lift the rear seat. The seat cushion is held by clips at the front: pull it up and forward. The fuel pump module service access cover is under the carpet.
  5. Remove the carpet and unscrew the access cover, which is held by screws or self-tapping screws. Vacuum the area around the flange so dirt does not fall into the tank.
  6. Disconnect the module's electrical connector. Then disconnect the fuel lines by pressing the release tabs of the quick-connect fittings. Place rags underneath, because residual fuel may spray out.
  7. Mark the position of the flange relative to the tank. Unscrew the plastic lock ring counterclockwise: use a wrench, or tap the tabs lightly with a brass drift. Do not hit the plastic with a metal hammer, as this can cause sparks and break the tabs.
  8. Carefully lift out the module, tilting it so you do not bend the fuel level sensor float arm. Let the fuel drain back into the tank.
  9. Disassemble the module on a workbench. Remove the filter element and the strainer (pre-filter sock) from the pump. The design of the clips and housings depends on the module version, so take photos of the assembly order.
  10. Install the new filter and strainer. Inspect the pump, the float and the wiring. If the filter is clogged with heavy sediment or rust, also check the tank for contamination.
  11. Replace the flange O-ring with a new one. Lightly lubricate it with clean gasoline, not with oil or grease.
  12. Install the module aligning the marks; the float must move freely. Tighten the lock ring by hand with light force until it stops, without a torque wrench. Do not overtighten, to avoid cracking the plastic.
  13. Connect the fuel lines (you should hear a click, then give each a tug by hand to check) and the connector. Reinstall the fuel pump fuse or relay and reconnect the battery.
  14. Turn the ignition on for 2-3 seconds and off several times so the pump builds up pressure. Inspect the flange for leaks and any smell of gasoline. Then start the engine and check for leaks again.
  15. Reinstall the access cover, carpet and seat. Check that there are no fuel system fault codes, and take a test drive on a level road to confirm there is no loss of power.

Common mistakes and warnings

  • Working with gasoline is dangerous: the vapors are explosive
  • Do not smoke, do not use extension cords or portable work lights near the access opening, and keep a fire extinguisher at hand
  • On a GDI engine, a high-pressure fuel pump (HPFP) sits downstream of the low-pressure pump, and leaks or dirt getting into the system can lead to expensive repairs
  • If you have no experience working on fuel systems, leave the job to a repair shop
  • If you have the 1.6 T-GDI turbo version, the principle is the same, but check which module version it uses