Procedure for removing and replacing the engine bay fuse box on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, including proper disconnection of electrical connections and mounting hardware.

Warnings

Tools required

Parts

• Engine bay fuse box assembly × 1 — Use OEM specification
• Fuse box mounting hardware kit (if damaged) × 1 — Use OEM specification

Preparation

1. Ensure vehicle is parked on level ground with parking brake engaged
2. Allow engine to cool completely for at least 2 hours if recently operated
3. Disconnect negative battery terminal and wait minimum 3 minutes
4. Photograph engine bay from multiple angles for reference during reassembly
5. Have replacement fuse box ready and verify correct part number matches vehicle VIN
6. Prepare labeled bags or containers for storing mounting hardware

Procedure

1. 1

   Remove fuse box cover
   Locate the engine bay fuse box on the driver's side of the engine compartment near the battery. Release the cover clips by pressing the tabs and lift the cover off. Note the fuse diagram on the underside of the cover for reference.
2. 2

   Document and remove all fuses and relays
   Using your phone or camera, photograph the exact position of all fuses and relays in the fuse box. Remove all fuses and relays using a fuse puller and store them in a labeled container maintaining their original positions. This prevents accidental misplacement during reinstallation.
3. 3

   Disconnect main power feed cables
   Locate the large power feed cables entering the top and bottom of the fuse box. Remove the terminal bolts securing these cables using a 10mm socket. Support the heavy cables to prevent strain on other connections. Mark each cable position with tape and marker for correct reinstallation.
   ⚠These cables carry high current. Ensure battery is disconnected and cables do not contact ground or other terminals during removal.
   Torque spec

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

   Disconnect electrical connectors
   Locate all electrical connectors plugged into the back and sides of the fuse box housing (typically 6-8 multi-pin connectors). Press the locking tabs and carefully disconnect each connector. Use a flathead screwdriver to gently release stubborn connector locks if necessary. Label each connector with numbered tape corresponding to its position.
5. 5

   Remove ground strap connections
   Identify the ground straps connected to the fuse box bracket or nearby mounting points. Remove the ground strap bolts using a 10mm socket. Clean the contact surfaces with a wire brush to remove any corrosion. Keep ground hardware separate for reinstallation.
   ℹ️Clean ground contact surfaces are critical for proper electrical system function. Corroded connections will cause intermittent electrical issues.
   Torque spec

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

   Remove air intake ducting (if required)
   On some configurations, the air intake duct may partially obstruct fuse box removal. Loosen the clamps on the air intake duct and reposition or remove it to gain full access to the fuse box mounting bolts. Set aside with clamps attached.
7. 7

   Remove fuse box mounting bolts
   Locate the fuse box mounting bolts securing the assembly to the fender/inner structure (typically 3-4 bolts). Remove the mounting bolts using a 12mm socket. Support the fuse box with one hand as you remove the final bolt to prevent it from falling.
   ⚠The fuse box assembly is heavier than it appears due to internal components. Support it during removal to prevent dropping.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
8. 8

   Remove fuse box assembly
   Carefully lift the fuse box assembly up and out of the engine bay, maneuvering around any remaining brackets or wiring. Inspect the mounting area for any damage, corrosion, or debris. Clean the mounting surface with a clean rag if necessary.
9. 9

   Prepare new fuse box
   Unbox the new fuse box and verify it matches the old unit exactly. Transfer any modules or components mounted to the old fuse box that are not included with the new unit. Remove module mounting bolts, carefully transfer modules, and reinstall securing with module mounting bolts.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
10. 10

    Install new fuse box assembly
    Position the new fuse box into the mounting location, aligning the mounting holes with the bracket. Thread in all mounting bolts by hand first to ensure proper alignment, then tighten to specification using a torque wrench in a cross-pattern.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect ground straps
    Reattach all ground straps to their original positions. Ensure contact surfaces are clean and free of corrosion. Torque ground strap bolts to specification. Verify straps are not pinched or stretched.
    Torque spec

    Ground Strap Bolts12 Nm (9 lb-ft)
12. 12

    Reconnect electrical connectors
    Reconnect all electrical connectors to the new fuse box in their original positions using your labels and photos as reference. Each connector should click firmly into place. Gently tug each connector to verify it is fully seated and locked.
    ⚠Forcing connectors into wrong positions can damage pins. Verify connector shape and pin count before connecting.
13. 13

    Reconnect main power feed cables
    Reconnect the main power feed cables to their terminals on the new fuse box using your markings as reference. Install terminal bolts and torque to specification using a torque wrench. Ensure cables are properly seated before tightening.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
14. 14

    Reinstall fuses and relays
    Using your photograph as a guide, reinstall all fuses and relays into their exact original positions in the new fuse box. Verify each fuse and relay is fully seated. Double-check positions against the fuse diagram on the cover.
15. 15

    Reinstall air intake and fuse box cover
    If removed, reinstall the air intake ducting and secure clamps. Install the fuse box cover ensuring all clips fully engage. Reconnect the negative battery terminal and torque to specification.
    ⚠Do not overtighten battery terminal bolt as this can crack the terminal or strip threads.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Ensure no tools or hardware are left in the engine bay
3. Confirm fuse box cover is properly secured with all clips engaged
4. Verify ground connections are tight and contact surfaces are clean

Verification

• Turn ignition to ON position (do not start) and verify dashboard lights illuminate normally
• Check for any warning lights that were not present before the repair
• Start the engine and verify normal operation with no abnormal warning lights
• Test all major electrical systems: headlights, wipers, windows, HVAC blower, turn signals, and horn
• Use a scan tool to check for any new fault codes and clear any codes related to battery disconnection
• Verify all fuses are in correct positions by testing associated circuits
• Inspect fuse box area for any signs of arcing, burning smell, or loose connections during initial operation
• Test drive vehicle and verify all electrical systems function normally including AWD system, traction control, and ABS

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