This procedure covers removal and replacement of the interior fuse box on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including battery disconnect, trim removal, and electrical connections.

Warnings

Tools required

Parts

• Interior fuse box assembly × 1 — Use OEM specification
• Trim panel clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Ensure ignition is OFF and key is removed from vehicle
3. Disconnect negative battery terminal and secure cable away from battery post
4. Wait minimum 3 minutes for airbag system discharge
5. Open driver's door and position driver's seat fully rearward for access
6. Photograph or document fuse positions and wiring connector orientations

Procedure

1. 1

   Remove lower dash trim panel
   Locate and remove the lower dash trim panel on the driver's side. Use trim removal tools to carefully release the retaining clips starting from the bottom edge and working upward. Pull the panel toward you and down to disengage the upper clips. Set panel aside in a safe location.
2. 2

   Remove fuse box access cover
   Open the interior fuse box cover by pulling the cover latch. Remove the cover screws if present and set aside. Remove the fuse diagram card and store for reference.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Document and remove fuses and relays
   Using the fuse diagram, photograph the positions of all fuses and relays. Remove all fuses and relays from the fuse box using the fuse puller tool (typically stored in the fuse box cover). Store in a labeled container maintaining position reference.
4. 4

   Disconnect wiring harness connectors
   Locate all wiring harness connectors on the back and sides of the fuse box. Press the release tabs on each connector and carefully pull straight out to disconnect. There are typically 3-5 large multi-pin connectors. Support the fuse box while disconnecting to prevent stress on mounting points.
   ⚠Do not pull on wires - pull only on connector housings to prevent terminal damage
5. 5

   Remove ground strap connections
   Locate the ground strap(s) connected to the fuse box or mounting bracket. Remove the ground strap bolts and disconnect the ground connections. Clean the contact surfaces with a wire brush or contact cleaner if corrosion is present.
   ℹ️Clean ground contact surfaces are critical for proper electrical system operation
   Torque spec

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

   Remove fuse box mounting bolts
   Locate the fuse box mounting bolts securing the assembly to the dash structure. There are typically 2-3 mounting bolts accessible from the front and side. Remove all mounting bolts using a 10mm socket, supporting the fuse box weight as you remove the final bolt.
   ⚠Fuse box may be heavier than expected - support weight before removing final mounting bolt
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
7. 7

   Remove fuse box assembly
   Carefully maneuver the fuse box assembly out of the dash cavity. Tilt and rotate as needed to clear surrounding components. Inspect the mounting area for any loose hardware or debris and clean if necessary.
8. 8

   Prepare replacement fuse box
   Inspect the new fuse box for any shipping damage or missing components. Verify part number matches the original. Transfer any brackets or mounting hardware from the old fuse box to the new unit if they are not pre-installed. Do not install fuses or relays yet.
9. 9

   Install replacement fuse box
   Position the new fuse box into the dash cavity, carefully maneuvering to align with mounting points. Start all mounting bolts by hand before tightening any. Once all bolts are started, tighten to specification using a torque wrench in a cross-pattern.
   Torque spec

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

    Reconnect ground straps
    Reconnect ground strap(s) to the fuse box or mounting bracket. Ensure mating surfaces are clean and free of paint or corrosion. Install ground strap bolts and torque to specification.
    Torque spec

    Ground Strap Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect wiring harness connectors
    Reconnect all wiring harness connectors to the fuse box, referring to your photos for correct positions. Push each connector firmly until you hear and feel the locking tab engage. Gently tug on each connector to verify it is fully locked.
    ⚠Ensure connectors are fully seated - partial connections can cause electrical issues or melted terminals
12. 12

    Install fuses and relays
    Referring to your documentation and the fuse diagram, install all fuses and relays in their correct positions. Ensure each fuse is fully seated in its socket. Verify amperage ratings match the diagram specifications.
13. 13

    Reinstall fuse box cover and trim
    Reinstall the fuse box access cover and tighten any cover screws to specification. Replace the fuse diagram card. Reinstall the lower dash trim panel by aligning the upper clips first, then pressing firmly around the perimeter to engage all retaining clips.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
14. 14

    Reconnect battery and initialize systems
    Reconnect the negative battery terminal and torque the battery terminal bolt to specification. Do not overtighten to prevent terminal damage. Turn ignition to ON position (do not start engine) and verify dashboard lights illuminate normally.
    ⚠Battery terminal bolts use low torque specification - overtightening will damage terminals
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all trim panels are properly secured with no gaps or loose clips
2. Set clock and radio presets as needed
3. Perform power window auto-up/down relearn procedure: fully lower window, then fully raise and hold switch up for 2 seconds
4. Clear any diagnostic trouble codes that may have set during battery disconnect

Verification

• Turn ignition to ON position and verify all dashboard warning lights illuminate then extinguish normally
• Start engine and verify it runs normally with no warning lights
• Test all circuits controlled by the interior fuse box including interior lights, power windows, HVAC blower, radio, and power outlets
• Verify no blown fuses after testing all circuits
• Check for proper operation of all safety systems including airbag indicator light
• Test all electrical accessories with engine running to confirm proper power distribution
• Inspect fuse box area for any unusual odors or heat after 5 minutes of operation

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