This procedure covers removal and replacement of the front power window regulator assembly on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Front window regulator assembly × 1 — Use OEM specification for driver or passenger side
• Door panel clips (if damaged) × 1 — Replace any broken during removal
• Vapor barrier sheet (if torn) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Roll the affected window fully up before beginning work
3. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge
4. Ensure you have the correct replacement regulator for driver or passenger side

Procedure

1. 1

   Remove door panel fasteners
   Remove the door handle trim cover by prying gently with trim tool. Remove one Phillips screw behind door handle. Remove door pull cup cover and remove two screws beneath. Use trim tool to release door panel clips starting from bottom edge and working around perimeter. Lift panel up and away from door frame.
2. 2

   Disconnect door panel connectors
   Disconnect electrical connectors for power window switch, power mirror switch, and any courtesy lighting. Note connector positions and routing. Set door panel aside in safe location to prevent scratches.
3. 3

   Remove vapor barrier
   Carefully peel back the plastic vapor barrier sheet to access the window regulator assembly. Work slowly to avoid tearing the barrier. If adhesive is insufficient for reuse, prepare replacement barrier.
4. 4

   Secure window glass
   Lower window approximately 6 inches to access glass-to-regulator bolts through access holes. Use masking tape to secure window glass in the up position once disconnected from regulator, taping glass to top of door frame.
5. 5

   Disconnect window from regulator
   Remove the two 10mm bolts securing window glass to regulator channel through access holes in door frame. Support glass as you remove final bolt. Carefully slide glass upward and secure with tape to door frame.
6. 6

   Disconnect regulator electrical connector
   Locate and disconnect the electrical connector for the window motor. Press release tab and pull connector straight out. Verify no wire harnesses are routed through regulator mounting area.
7. 7

   Remove regulator mounting bolts
   Remove the regulator assembly mounting bolts. There are typically 4-6 bolts securing the regulator and motor assembly to the door frame. Use 10mm socket to remove all mounting hardware.
   Torque spec

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

   Extract regulator assembly
   Carefully maneuver the regulator assembly and motor through the large access opening in the door frame. The assembly may need to be tilted and rotated to clear obstructions. Guide wire cables through openings carefully to prevent kinking.
9. 9

   Install new regulator assembly
   Position new regulator assembly and guide it through access opening into door frame. Align mounting holes with door frame. Ensure regulator cables are not twisted or kinked. Start all mounting bolts by hand before tightening.
10. 10

    Torque regulator mounting bolts
    Torque all regulator mounting bolts to specification in a cross pattern to ensure even mounting pressure. Verify regulator sits flush against door frame with no gaps.
    Torque spec

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

    Reconnect electrical connector
    Connect electrical connector to window motor. Ensure connector clicks fully into place and locking tab engages. Route harness away from moving components.
12. 12

    Test regulator operation
    Temporarily reconnect battery negative terminal and test regulator operation before attaching window glass. Window regulator should move smoothly up and down through full range without binding or unusual noise. Disconnect battery again before proceeding.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
13. 13

    Attach window glass to regulator
    Remove tape securing window glass. Lower glass carefully into regulator channel. Align mounting holes and install two 10mm bolts finger-tight. Adjust glass position to ensure proper alignment in door frame, then torque bolts to specification.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
14. 14

    Reinstall vapor barrier and door panel
    Press vapor barrier back into place ensuring complete seal around perimeter. Reconnect all door panel electrical connectors. Position door panel and engage top edge into window channel. Press firmly around perimeter to engage all clips. Reinstall all screws and covers.

Reassembly

1. Ensure all door panel clips are fully seated and panel is flush with door frame
2. Verify all trim pieces and covers are properly installed and secure
3. Reconnect negative battery terminal and torque to specification

Verification

• Test window operation through full up and down cycle multiple times
• Verify window seats properly in fully closed position with no gaps
• Check that window moves smoothly without binding, unusual noise, or slow operation
• Verify door panel is secure with no rattles when door is closed firmly
• Test one-touch up/down auto function if equipped, perform window relearn procedure if necessary

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