This procedure covers removal and replacement of the positive battery cable on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, including disconnection from the battery terminal and all attached harness connections.

Warnings

Tools required

Parts

• Positive battery cable assembly × 1 — Use OEM specification
• Cable routing clips (as needed) × 1 — Use OEM specification
• Cable ties × 5 — Assorted sizes

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all electrical accessories and remove key from ignition
3. Allow engine to cool if recently driven
4. Open hood and locate battery in engine compartment (driver side)
5. Take photographs of positive cable routing from multiple angles for reference during reinstallation

Procedure

1. 1

   Disconnect negative battery terminal
   Using a 10mm socket, loosen the negative (-) battery terminal bolt completely. Remove the terminal from the battery post and position it away from the battery to prevent accidental contact. Secure it to prevent movement.
2. 2

   Disconnect positive battery terminal
   Using a 10mm socket, loosen the positive (+) battery terminal bolt. Carefully remove the positive terminal from the battery post. Keep terminal away from any metal surfaces to prevent shorting.
   ⚠The positive terminal is live until disconnected - avoid contact with metal surfaces
3. 3

   Remove battery hold-down (if necessary)
   If the battery hold-down bracket interferes with cable removal, use a 12mm socket to remove the battery hold-down bolt. Lift the hold-down bracket away and set aside. Remove battery if additional access is needed.
4. 4

   Trace and document cable routing
   Follow the positive cable from the battery terminal through the engine bay, noting all attachment points, clips, and connections. The cable typically routes to the starter motor and fuse box. Identify all junction points and connections that must be separated.
5. 5

   Disconnect cable at fuse box junction
   Locate where the positive cable connects to the main fuse box (typically near the battery). Remove the protective cover if present. Use a 10mm or 12mm socket to remove the mounting bolt securing the cable terminal to the fuse box junction point. Carefully lift the terminal away.
6. 6

   Disconnect cable at starter motor
   Locate the starter motor on the transmission bell housing. The positive cable connects to the starter solenoid terminal. Remove the protective rubber cover. Using a 12mm socket, remove the nut securing the cable terminal to the starter post. Remove the cable terminal.
7. 7

   Release cable from routing clips
   Working along the cable path, release the cable from all plastic routing clips and cable tie anchors. Cut cable ties as needed using cable tie cutter. Note the location of each clip for proper reinstallation. Remove any protective conduit or wire loom covering the cable.
8. 8

   Remove old positive cable
   Once all connections and clips are released, carefully remove the positive battery cable from the vehicle. Inspect the cable routing path and clean any corrosion from mounting points and connection surfaces using a wire brush.
9. 9

   Install new positive cable
   Route the new positive cable along the same path as the old cable, using reference photos taken earlier. Ensure the cable does not contact sharp edges, hot surfaces, or moving components. Verify sufficient slack at all connection points before securing.
10. 10

    Connect cable at starter motor
    Place the cable terminal onto the starter solenoid post. Install the retaining nut and tighten using a 12mm socket. Ensure the connection is clean and secure. Reinstall the protective rubber cover over the terminal.
11. 11

    Connect cable at fuse box junction
    Position the cable terminal onto the fuse box junction point. Install the mounting bolt and tighten securely using a 10mm or 12mm socket. Ensure the terminal makes full contact with the connection surface. Replace any protective covers.
12. 12

    Secure cable routing
    Install the cable into all routing clips along its path. Use new cable ties to secure the cable at original anchor points. Ensure the cable has no tight bends, is not stretched, and maintains clearance from moving or hot components. Verify routing matches reference photos.
13. 13

    Reinstall battery (if removed)
    If the battery was removed, place it back into the battery tray. Install the hold-down bracket and secure with the hold-down bolt. Tighten to specification using torque wrench.
    Torque spec

    Battery Hold-Down Bolt11 Nm (8 lb-ft)
14. 14

    Connect positive battery terminal
    Clean the positive battery post with a battery terminal cleaner or wire brush. Apply a thin coat of dielectric grease to the post. Install the positive cable terminal onto the battery post, ensuring it is fully seated. Tighten the terminal bolt to specification using a torque wrench and 10mm socket.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
15. 15

    Reconnect negative battery terminal
    Clean the negative battery post with a battery terminal cleaner or wire brush. Apply a thin coat of dielectric grease. Install the negative cable terminal onto the battery post, ensuring full contact. Tighten the terminal bolt to specification using a torque wrench and 10mm socket.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all cable connections are tight and properly torqued
2. Ensure cable routing does not interfere with any moving parts or contact hot surfaces
3. Confirm all protective covers are reinstalled over terminals
4. Test operation of all electrical systems before closing hood

Verification

• Turn ignition to ON position and verify dashboard lights illuminate normally
• Start the engine and confirm normal operation
• Test headlights, horn, and power windows to verify electrical system function
• Check for any warning lights on the instrument cluster
• Verify no melting smells or excessive heat at cable connections after running engine for several minutes
• Reset clock and radio presets as needed

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