This procedure covers the removal and replacement of a generic automotive relay in the engine compartment or interior fuse/relay box of a 2016-2024 Hyundai Tucson with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Replacement relay × 1 — Match amperage and part number on original relay

Preparation

1. Identify the specific relay to be replaced using owner's manual fuse/relay diagram or underhood relay box cover legend
2. Verify ignition is off and key is removed from vehicle
3. If replacing a relay for a circuit that remains powered with key off (fuel pump, ECM keep-alive, etc.), disconnect negative battery terminal
4. Photograph relay location if multiple similar relays are present
5. Note relay orientation and terminal configuration before removal

Procedure

1. 1

   Access relay box
   For engine compartment relays: open hood and locate the main fuse/relay box typically on driver side near battery. For interior relays: locate fuse panel on driver side lower dash or kick panel. Remove cover by releasing retaining clips - covers typically pull straight up or have twist-lock mechanisms.
2. 2

   Identify target relay
   Use the legend printed on the relay box cover or in owner's manual to identify the specific relay position. Relay positions are typically numbered or labeled by function (fuel pump relay, A/C compressor relay, etc.). Verify the relay amperage rating matches the specification for the circuit.
3. 3

   Test relay function (optional diagnostic step)
   If diagnosing a fault, use a multimeter to check for power at the relay socket when key is in appropriate position. Listen for relay click when activated. This confirms the issue is relay failure versus wiring or control module fault. A known-good relay can be swapped from an identical position to test.
4. 4

   Remove relay
   Grasp relay firmly with relay puller tool or needle-nose pliers. Pull straight up with steady, even pressure - avoid rocking side to side which can bend terminals. Some relays have a small tab that must be pressed while pulling. If resistance is encountered, verify no retaining clip is present and check for corrosion binding terminals.
5. 5

   Inspect relay socket
   Examine the relay socket terminals for corrosion, burning, discoloration, or damage. Check for pushed-back terminals or foreign material. If corrosion is present, clean terminals with electrical contact cleaner and allow to dry. Damaged sockets require relay box replacement or terminal repair.
6. 6

   Verify replacement relay specifications
   Compare new relay to old relay. Verify amperage rating, terminal configuration, and part number match. Relays may look identical but have different internal ratings - using incorrect relay can cause immediate failure or intermittent operation. Hyundai relays typically show ratings on the side: verify voltage (12V), amperage (typically 20A-40A), and terminal count match.
7. 7

   Install new relay
   Orient new relay to match terminal configuration of socket - terminals are offset or keyed to prevent incorrect installation. Align relay terminals with socket and press straight down with firm, even pressure until relay seats fully and is flush with adjacent relays. Relay should click or seat positively - do not force if significant resistance is encountered.
8. 8

   Reinstall relay box cover
   Align cover with relay box ensuring no wires are pinched. Press cover down until retaining clips engage fully. If cover has screws, reinstall and torque to specification to ensure weatherproof seal on engine compartment boxes.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)

Reassembly

1. If battery was disconnected, reconnect negative terminal and torque battery terminal bolt to 6.0 Nm (4.0 lb-ft)
2. Ensure relay box cover is fully seated and latched to prevent water intrusion on engine compartment installations
3. Reset clock, radio presets, and power windows as needed after battery reconnection

Verification

• Turn ignition to ON position and verify no new warning lights are illuminated on instrument cluster
• Activate the system controlled by the replaced relay (A/C compressor, fuel pump, cooling fan, etc.) and verify proper operation
• Listen for relay click when system activates - this confirms relay is receiving signal and switching properly
• For intermittent failures, test system multiple times over several minutes to confirm repair
• Verify no blown fuses resulted from relay replacement - check fuse associated with relay circuit

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