electrical

Starter Solenoid

for 2021 Hyundai Tucson 2.5L I4 · AWD

Difficulty

Moderate

Time

2.0 h

Tools

Steps

This procedure covers the removal and replacement of the starter solenoid (or complete starter assembly if solenoid is non-serviceable) on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine.

Warnings

⚠️Always disconnect the negative battery terminal first and reconnect it last to prevent electrical shorts and potential airbag deployment.

⚠The starter is heavy (approximately 8-10 lbs). Support it properly when removing the mounting bolts to prevent it from falling.

⚠Do not allow metal tools to bridge battery terminals or starter terminals to ground, as this will cause a direct short.

ℹ️On most 2016-2024 Tucson models with the 2.5L engine, the starter solenoid is integral to the starter assembly and cannot be replaced separately. Verify before ordering parts.

Tools required

10mm socket and ratchetEssential

12mm socket and ratchetEssential

13mm socket and ratchetEssential

14mm socket and ratchetEssential

Torque wrench (5-50 Nm range)Essential

Extension set (3-inch and 6-inch)Essential

Universal joint

Battery terminal puller

Wire brush

Penetrating oil

Jack and jack standsEssential

Work light or flashlightEssential

Parts

Starter assembly (if solenoid non-serviceable) × 1 — 36100-2GTA0 or equivalent OEM
Starter solenoid (if serviceable separately) × 1 — Use OEM specification

Preparation

Park vehicle on level ground and engage parking brake
Allow engine to cool completely if recently operated
Raise front of vehicle and support securely on jack stands
Remove engine splash shield (if equipped) for better access
Ensure you have proper lighting for underbody work

Procedure

1
Disconnect battery negative terminal
Open the hood and locate the battery. Using a 10mm wrench, loosen the negative (-) battery terminal bolt and carefully remove the cable. Secure the cable away from the battery post to prevent accidental reconnection. Wait at least 3 minutes for capacitors to discharge.
⚠️Never disconnect the positive terminal first, as this increases risk of short circuit if tools contact grounded metal.
Torque spec
Battery Terminal Bolts6 Nm (4 lb-ft)
2
Access starter from underneath
Position yourself under the vehicle with proper lighting. The starter is located on the passenger side (right side) of the engine block, near the transmission bellhousing. Identify the starter motor, electrical connections, and mounting bolts. Note the routing of all wiring before removal.
3
Disconnect starter electrical connections
Locate the main battery cable connection on the starter solenoid (large terminal with protective cap) and the signal wire connector (smaller plug). Remove the protective rubber cap from the battery terminal. Using a 12mm or 13mm socket (depending on model year), remove the battery cable nut from the solenoid. Disconnect the signal wire connector by pressing the release tab and pulling straight out. Label or photograph connections for proper reinstallation.
⚠The battery cable terminal may have residual voltage. Avoid contact with grounded surfaces.
Torque spec
Battery Cable Nut14 Nm (10 lb-ft)
4
Remove upper starter mounting bolt
Locate the upper starter mounting bolt accessible from above or below depending on clearance. Using a 14mm socket with extension and possibly a universal joint, remove the upper starter mounting bolt completely. This bolt threads into the transmission bellhousing. Support the starter with one hand as you remove the bolt.
Torque spec
Mounting Bolts34 Nm (25 lb-ft)
5
Remove lower starter mounting bolt
Working from underneath the vehicle, locate and remove the lower starter mounting bolt using a 14mm socket and ratchet. This bolt is typically more accessible than the upper bolt. Keep the bolt and any washers or spacers in a safe location.
Torque spec
Mounting Bolts34 Nm (25 lb-ft)
6
Remove starter assembly
With both mounting bolts removed, carefully work the starter assembly out of the bellhousing. The starter may need to be rotated or angled to clear the engine and transmission mounting points. Support the weight of the starter (approximately 8-10 lbs) as you pull it free. Lower the starter carefully to avoid damage to electrical terminals or housing.
⚠The starter is heavier than it appears. Use both hands and maintain secure grip to prevent dropping.
7
Inspect and replace solenoid or complete assembly
Inspect the starter assembly. On most Tucson 2.5L models, the solenoid is integrated and cannot be serviced separately - the entire starter must be replaced. If your model has a serviceable solenoid (verify with parts supplier), remove the mounting screws securing the solenoid to the starter housing using appropriate socket. Clean all mounting surfaces on the new or remanufactured starter assembly. Verify the new unit matches the original in terminal configuration and mounting bolt pattern.
8
Install starter assembly
Guide the new or repaired starter assembly into position, aligning the mounting holes with the bellhousing. The starter nose should fit snugly into the bellhousing opening. Ensure no wires are pinched and that the starter sits flush against the mounting surface. Hand-thread both mounting bolts to prevent cross-threading.
9
Torque starter mounting bolts
Using a torque wrench and 14mm socket, tighten both starter mounting bolts to specification in a cross pattern (alternate between upper and lower). First torque the upper bolt, then the lower bolt, then verify both are at proper specification. Ensure the starter does not shift during tightening.
⚠Under-torquing can allow starter movement and gear misalignment. Over-torquing can crack the bellhousing or strip threads.
Torque spec
Mounting Bolts34 Nm (25 lb-ft)
10
Reconnect electrical connections
Route the signal wire to the small terminal on the solenoid and press the connector firmly until it clicks into place. Position the main battery cable over the large solenoid terminal stud. Install the battery cable nut and hand-tighten. Using a 12mm or 13mm socket and torque wrench, tighten the battery cable nut to specification. Reinstall the protective rubber cap over the battery terminal connection.
⚠Ensure the battery cable connection is clean and tight. A loose connection will cause starting problems and potential arcing.
Torque spec
Battery Cable Nut14 Nm (10 lb-ft)
11
Reinstall underbody components
If the engine splash shield was removed, reinstall it using the original fasteners. Verify all tools and parts have been removed from under the vehicle. Lower the vehicle from jack stands to the ground.
12
Reconnect battery negative terminal
Clean the battery terminal post and cable end with a wire brush if corrosion is present. Position the negative cable over the negative battery post. Hand-tighten the terminal bolt, then use a torque wrench with 10mm socket to tighten to specification. Ensure the connection is secure with no movement.
ℹ️Over-tightening battery terminal bolts can crack the terminal or strip threads. Use specified torque only.
Torque spec
Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

Verify all electrical connections are secure and properly routed away from hot or moving components
Ensure no tools or parts remain in the engine compartment or under the vehicle
Double-check that both starter mounting bolts are torqued to specification

Verification

Turn the ignition key to the ON position (do not start) and verify all dashboard warning lights function normally
Attempt to start the engine - it should crank smoothly without grinding or clicking noises
Listen for unusual noises during cranking such as grinding (gear misalignment) or clicking (electrical issue)
Verify the engine starts promptly and the starter disengages immediately after engine fires
After successful start, turn off the engine and check for any unusual smells or smoke from the starter area
Perform a second start cycle to confirm consistent operation
Inspect starter electrical connections for signs of heat or arcing after test starts