This procedure covers removal and replacement of a side airbag module in the front seat of a 2016-2024 Hyundai Tucson with 2.5L I4 engine.

Warnings

Tools required

Parts

• Side airbag module (seat-mounted) × 1 — Use OEM specification - side-specific
• Airbag connector retaining clip (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn ignition to OFF position and remove key/fob from vehicle entirely
3. Open driver's door and leave open throughout procedure to prevent accidental lockout
4. Disconnect negative battery terminal and isolate cable away from battery post
5. Wait minimum 3 minutes for airbag system capacitors to fully discharge - set timer to ensure full wait time
6. Verify airbag warning light is not illuminated on instrument cluster before proceeding
7. Move seat to full forward position for easier access to mounting bolts
8. Adjust seat to lowest height position

Procedure

1. 1

   Remove seat from vehicle
   Locate four seat mounting bolts at base of seat rails (two front, two rear). Using appropriate socket and extension, remove all four seat mounting bolts. Carefully tilt seat backward and disconnect any electrical connectors at seat base (seat heater, power seat controls if equipped). With assistant, lift seat from vehicle and place on clean, protected work surface away from work area.
   ⚠Seat is heavy (approximately 50-70 lbs). Use proper lifting technique or get assistance to avoid injury.
   ⚠Do not disconnect yellow airbag connectors at this stage - only disconnect non-airbag electrical connections.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
2. 2

   Access side airbag module
   With seat on work surface, locate side trim panel on outboard side of seat backrest (side closest to door when installed). Identify plastic clips or fasteners securing trim panel. Using trim removal tools, carefully release clips starting from bottom edge and working upward. Remove side trim panel to expose seat frame and airbag module. Note routing of any wiring harnesses for reassembly.
3. 3

   Locate airbag connector
   Identify the yellow airbag connector attached to side airbag module. This connector has a distinctive yellow color and locking mechanism. Note connector orientation and any cable routing clips. Do not disconnect yet - visually inspect connector and locking mechanism to understand release procedure.
   ⚠️Yellow connectors indicate airbag circuit. Never pull on wires - always grasp connector body when disconnecting.
4. 4

   Disconnect airbag electrical connector
   Locate connector lock mechanism (typically a sliding lock or flip-up tab on yellow connector). Carefully release lock mechanism. Grasp connector body firmly (not wires) and disconnect by pulling straight apart. Do not twist or bend connector. Once disconnected, route connector away from module and secure so it cannot contact metal surfaces.
   ⚠️After disconnecting, do not allow connector pins to contact metal or each other. This could cause accidental deployment when battery is reconnected.
5. 5

   Remove airbag module mounting hardware
   Locate side airbag module mounting bolts securing module to seat frame (typically 2-4 Torx bolts). Using appropriate Torx driver (typically T30 or T40), remove all mounting bolts. Keep bolts organized as they must be reused with proper torque. Note exact position and orientation of airbag module for installation of replacement.
   ⚠Airbag module may be under slight tension from seat upholstery. Support module while removing final bolt to prevent dropping.
   Torque spec

   Side Airbag Module Bolts7 Nm (5 lb-ft)
6. 6

   Remove airbag module from seat
   Carefully extract airbag module from seat backrest frame. Module may be partially embedded in foam padding. Work slowly to avoid tearing seat upholstery or damaging surrounding foam. Once free, immediately place module with trim cover facing UP on clean surface, away from work area. Never place anything on top of removed airbag module.
   ⚠️Treat removed airbag as live explosive device. Store in secure area away from heat, moisture, and electrical sources until proper disposal through authorized facility.
7. 7

   Inspect mounting area
   Examine seat frame mounting points for any damage, cracks, or deformation. Verify mounting bolt holes are clean and threads are undamaged. Check wiring harness for any signs of damage, chafing, or previous improper repair. Inspect seat upholstery opening for tears or excessive wear. Clean mounting area of any debris or foam particles.
8. 8

   Prepare new airbag module
   Remove new airbag module from packaging carefully. Verify part number matches original module and is correct for vehicle year and seat position (driver vs passenger). Inspect new module for any shipping damage. Do not remove any protective covers from deployment side. Position module with same orientation as removed unit.
   ⚠️Never install airbag module that has been dropped, impacted, or shows any physical damage. Return to supplier for replacement.
   ℹ️Driver and passenger side airbag modules may be different part numbers. Verify correct side before installation.
9. 9

   Install new airbag module
   Carefully position new airbag module into seat backrest frame in exact same orientation as original. Align mounting bolt holes with frame holes. Start all mounting bolts by hand to ensure proper thread engagement before tightening any bolts. Using calibrated torque wrench with appropriate Torx bit, torque all side airbag module bolts to specification in cross-pattern sequence.
   ⚠Critical torque specification. Under-torquing can allow module movement during deployment. Over-torquing can damage module housing or frame threads.
   Torque spec

   Side Airbag Module Bolts7 Nm (5 lb-ft)
10. 10

    Reconnect electrical connector
    Route airbag wiring harness along original path, securing in any routing clips. Align yellow airbag connector with module connector, ensuring correct orientation (connectors are keyed and will only fit one way). Push connector together firmly until you hear/feel positive click. Engage connector locking mechanism fully. Gently tug on connector to verify it is fully locked - it should not separate.
    ⚠Connector must be fully seated and locked. Partial connection can prevent airbag deployment or cause false diagnostic codes.
11. 11

    Reinstall seat trim panel
    Verify all wiring is properly routed and will not be pinched by trim panel. Position side trim panel, aligning all clip locations with corresponding holes in seat frame. Starting from top, press firmly to engage each clip until fully seated. Verify panel is flush and secure around entire perimeter with no gaps.
12. 12

    Reinstall seat in vehicle
    With assistant, carefully lift seat and position over mounting points in vehicle. Reconnect any non-airbag electrical connectors at seat base (heater, power controls). Align seat rails with floor mounting holes. Install all four seat mounting bolts and hand-tighten. Using calibrated torque wrench, torque all four seat mounting bolts to specification in cross-pattern.
    ⚠Seat mounting bolts are safety-critical. Ensure proper torque is achieved on all four bolts. Loose seat can cause injury in collision.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
13. 13

    Reconnect battery and verify operation
    Reconnect negative battery terminal. Turn ignition to ON position without starting engine. Observe airbag warning light on instrument cluster - it should illuminate for approximately 6 seconds then extinguish. If light remains on or flashes, do not operate vehicle. Connect OBD-II scanner and check for airbag diagnostic trouble codes.
    ⚠️If airbag warning light does not function as described, system may be inoperative. Vehicle must not be driven until fault is diagnosed and corrected by qualified technician.
14. 14

    Clear diagnostic codes and final verification
    Using OBD-II scanner with airbag system capability, clear any stored diagnostic trouble codes related to airbag disconnection during service. Cycle ignition OFF then ON again. Verify airbag warning light performs normal self-test (illuminates then extinguishes). Re-scan for codes to confirm no active faults present. Test seat movement through full range of adjustment to ensure no interference with new module.

Reassembly

1. Ensure all seat adjustments (fore/aft, recline, height if equipped) operate smoothly without binding or interference
2. Verify seat trim panel is fully secured with no gaps or loose clips
3. Confirm all electrical connections at seat base are properly engaged
4. Double-check that all four seat mounting bolts are torqued to specification

Verification

• Airbag warning light illuminates for approximately 6 seconds at ignition ON, then extinguishes completely
• No diagnostic trouble codes present in airbag system when scanned
• Seat operates normally through all adjustment ranges
• Side trim panel is secure and properly aligned
• Yellow airbag connector is fully locked and secure
• Seat does not move or shift when mounting bolts are verified at proper torque
• Perform final visual inspection of yellow connector to ensure locking mechanism is fully engaged

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