This procedure covers the removal and replacement of both positive and negative battery cables on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine and AWD.

Warnings

Tools required

Parts

• Positive battery cable assembly × 1 — Use OEM specification
• Negative battery cable assembly × 1 — Use OEM specification
• Battery terminal anti-corrosion washers (if equipped) × 2 — Use OEM specification

Preparation

1. Ensure the vehicle is parked on a level surface with the engine off and cooled
2. Turn off all electrical accessories including lights, radio, and HVAC
3. Remove the key fob from the vehicle to prevent accidental activation
4. Open the hood and secure it with the prop rod
5. Locate the battery in the left front corner of the engine compartment
6. Inspect battery cables for damage, corrosion, or wear to confirm replacement is needed
7. Take a photo or note routing of cables before removal for reference during installation

Procedure

1. 1

   Disconnect negative battery cable
   Using a 10mm socket, loosen the bolt securing the negative (black) battery terminal clamp. Remove the cable from the battery post and secure it away from the battery to prevent accidental contact. Do not allow the cable to touch any metal surface.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Disconnect positive battery cable
   Using a 10mm socket, loosen the bolt securing the positive (red) battery terminal clamp. Remove the cable from the battery post. Cover the terminal end with a shop towel or insulating material to prevent accidental grounding.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
3. 3

   Remove battery hold-down
   Using a 10mm socket, remove the battery hold-down bracket bolt and remove the hold-down clamp. Carefully lift the battery straight up and out of the battery tray. Set aside in a safe location.
   ⚠Battery weighs approximately 35-40 lbs - lift with proper technique to avoid injury
   Torque spec

   Battery Hold-Down Bolt11 Nm (8 lb-ft)
4. 4

   Remove positive cable connections
   Trace the positive cable to its connection points. Disconnect the positive cable from the starter solenoid and any junction blocks or fuse boxes by removing the retaining nuts (typically 12mm or 13mm). Note the routing and any cable clips or ties. Remove the cable from the vehicle.
5. 5

   Remove negative cable ground connections
   Trace the negative cable to its ground point on the engine block and chassis. Using a 12mm or 13mm socket, remove the bolts securing the ground cable terminals. Remove any ground straps connected to the battery tray or body. Note the exact location and layering order of ground terminals. Remove the cable from the vehicle.
   Torque spec

   Ground Cable Bolt14 Nm (10 lb-ft)

   Ground Strap Bolts12 Nm (9 lb-ft)
6. 6

   Clean battery tray and terminal surfaces
   Clean the battery tray, hold-down bracket, and any corrosion from mounting points using a wire brush and baking soda solution if needed. Dry thoroughly. Clean all ground contact surfaces on the engine block and chassis using a wire brush to ensure bare metal contact.
7. 7

   Install new negative battery cable
   Route the new negative cable following the same path as the original. Attach ground terminals to the engine block and chassis ground points in the same layering order as removed. Hand-tighten bolts first, then torque to specification using a torque wrench. Ensure clean metal-to-metal contact at all ground points.
   ⚠Ground connections are critical for proper electrical system operation - ensure surfaces are clean and torque is correct
   Torque spec

   Ground Cable Bolt14 Nm (10 lb-ft)

   Ground Strap Bolts12 Nm (9 lb-ft)
8. 8

   Install new positive battery cable
   Route the new positive cable following the same path as the original. Secure any cable clips or ties to prevent chafing. Connect the cable to the starter solenoid and junction blocks/fuse boxes. Hand-tighten nuts first, then torque to specification. Ensure connections are tight and secure.
9. 9

   Reinstall battery
   Clean battery posts with a wire brush or terminal cleaner. Place the battery back into the tray with posts oriented correctly (positive toward front of vehicle). Install the hold-down clamp and bolt. Torque the hold-down bolt to specification - do not overtighten as this can damage the battery case.
   Torque spec

   Battery Hold-Down Bolt11 Nm (8 lb-ft)
10. 10

    Connect positive battery cable
    Clean the positive battery post and cable terminal with a wire brush. Place the positive (red) cable terminal onto the positive battery post. Install and hand-tighten the terminal bolt, then torque to specification. Apply dielectric grease to the connection if desired.
    ⚠Do not overtighten terminal bolts as this can strip threads or crack the terminal clamp
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
11. 11

    Connect negative battery cable
    Clean the negative battery post and cable terminal with a wire brush. Place the negative (black) cable terminal onto the negative battery post. Install and hand-tighten the terminal bolt, then torque to specification. Apply dielectric grease to the connection if desired.
    ℹ️Expect a small spark when making final negative connection - this is normal as vehicle systems initialize
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify both battery cables are securely connected and properly torqued
2. Ensure no tools or materials are left in the engine compartment
3. Close the hood securely

Verification

• Turn the ignition to ON position (do not start) and verify dashboard lights illuminate normally
• Start the engine and verify it starts normally without extended cranking
• Check that all electrical systems function properly: lights, radio, windows, climate control
• Verify no warning lights remain on the dashboard related to charging system
• Perform power window auto-up/down initialization if needed: fully lower each window, then fully raise and hold button for 2 seconds
• Reset clock and radio presets as needed
• Inspect battery cable connections for any signs of heat, smoking, or loose connections after 5 minutes of operation
• If equipped with sunroof, perform sunroof initialization procedure per owner's manual if auto-close function does not work

More procedures for this vehicle