This procedure covers the removal and replacement of the starter motor on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including disconnecting the battery, accessing the starter from below, and reinstalling with proper torque specifications.

Warnings

Tools required

Parts

• Starter motor × 1 — Use OEM specification or quality aftermarket

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow engine to cool completely if recently driven
4. Ensure ignition is off and key is removed from vehicle
5. Gather all tools and new starter motor before beginning

Procedure

1. 1

   Disconnect battery
   Open the hood and locate the battery in the engine compartment. Using a 10mm socket, loosen the negative (-) battery cable nut and remove the cable from the terminal. Secure the cable away from the battery to prevent accidental contact. Wait at least 3 minutes for capacitors to discharge.
2. 2

   Raise and support vehicle
   Lift the front of the vehicle using a floor jack at the designated jacking points. Place jack stands under the frame rails on both sides. Lower the vehicle onto the jack stands and verify stability before proceeding. The starter is accessed from below on this vehicle.
   ⚠️Never work under a vehicle supported only by a jack
3. 3

   Remove engine undercover (if equipped)
   If your vehicle has a plastic engine undercover or splash shield, remove the fasteners securing it using a 10mm socket or appropriate tool. Some fasteners may be push-pin style. Set the shield aside to access the starter area.
4. 4

   Locate starter motor
   Position yourself under the vehicle and locate the starter motor on the lower front section of the engine, where the engine meets the transmission bellhousing. The starter will be cylindrical with electrical connections on the back side. On AWD models, the front differential and transfer case are nearby, so identify the correct component.
5. 5

   Disconnect starter electrical connections
   Identify the two electrical connections on the starter: the B+ cable (thick red wire with nut) and the signal wire connector (small push-on connector). Using a 12mm socket, remove the nut securing the B+ cable and move the cable aside. Disconnect the signal wire connector by pressing the release tab and pulling straight off.
   ⚠Do not pull on wires; support the connector while removing to avoid damage
   Torque spec

   Starter Solenoid Nut12 Nm (9 lb-ft)
6. 6

   Remove heat shield (if present)
   Some models have a heat shield covering or near the starter. If present, remove the heat shield bolts using a 10mm socket and set the shield aside for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
7. 7

   Remove starter mounting bolts
   Locate the two or three starter mounting bolts that secure the starter to the bellhousing. Using a 14mm or 17mm socket with extensions, remove all mounting bolts. The long upper bolt may require a 10-12 inch extension to reach. Keep track of bolt locations as lengths may vary.
   ⚠Support the starter with one hand while removing the final bolt to prevent it from falling
   Torque spec

   Starter Mounting Bolts50 Nm (37 lb-ft)
8. 8

   Remove starter motor
   With all mounting bolts removed, carefully pull the starter straight out from the bellhousing. The starter nose may be snug in the pilot hole, so wiggle gently if needed. Lower the starter down and out from underneath the vehicle. Inspect the mounting surface and pilot hole on the bellhousing for debris or damage.
9. 9

   Prepare new starter
   Compare the new starter to the old unit to verify correct application, checking mounting bolt pattern, nose cone length, and electrical terminal positions. Clean the bellhousing mounting surface with a wire brush if needed. Verify the starter drive gear rotates freely by hand.
10. 10

    Install new starter motor
    Position the new starter up into the bellhousing opening from below. Align the starter nose with the pilot hole and push the starter fully into position. Ensure the starter sits flush against the bellhousing before installing bolts. Thread all mounting bolts by hand first to ensure proper alignment.
11. 11

    Torque starter mounting bolts
    Using a torque wrench, tighten the starter mounting bolts to 50.0 Nm (37.0 lb-ft) in a cross pattern if multiple bolts are used. Ensure an extension is used for the long upper bolt. Verify the starter is seated properly and does not move when torqued.
    Torque spec

    Starter Mounting Bolts50 Nm (37 lb-ft)
12. 12

    Reinstall heat shield
    If a heat shield was removed, position it back in place and install the mounting bolts. Torque the heat shield bolts to 10.0 Nm (7.0 lb-ft).
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
13. 13

    Reconnect starter electrical connections
    Reconnect the signal wire connector to the starter solenoid terminal, pressing until it clicks into place. Position the B+ cable over the solenoid stud and install the retaining nut. Torque the B+ cable nut to 12.0 Nm (9.0 lb-ft) using a torque wrench.
    ⚠Ensure no wires are pinched or touching hot exhaust components
    Torque spec

    Starter Solenoid Nut12 Nm (9 lb-ft)
14. 14

    Reinstall engine undercover and lower vehicle
    If the engine undercover was removed, reinstall it and secure all fasteners. Raise the vehicle slightly with the jack, remove the jack stands, and carefully lower the vehicle to the ground.
15. 15

    Reconnect battery
    Reconnect the negative battery cable to the negative terminal. Torque the battery cable nut to 14.0 Nm (10.0 lb-ft) using a torque wrench. Ensure the connection is tight and clean.

Reassembly

1. Double-check that all electrical connections are secure and properly routed
2. Verify all mounting bolts are torqued to specification
3. Ensure no tools or parts were left in the engine compartment or under the vehicle

Verification

• Turn the ignition key to the ON position (not START) and verify no warning lights related to the starter system appear
• Attempt to start the engine. The starter should engage smoothly without grinding or hesitation
• Listen for unusual noises during cranking. The starter should disengage immediately once the engine starts
• Perform 3-5 start cycles to verify consistent operation
• Inspect under the vehicle for any signs of fluid leaks or loose components disturbed during the repair

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