This procedure covers the removal and replacement of the air suspension height sensor on a 2016-2024 Hyundai Tucson with 2.5L I4 engine and AWD.

Warnings

Tools required

Parts

• Air suspension height sensor × 1 — Use OEM specification
• Sensor mounting hardware kit × 1 — Use OEM specification if corroded

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind front wheels
3. Turn ignition to OFF position but do NOT disconnect battery
4. Allow air suspension to settle for 2-3 minutes if vehicle was recently driven
5. Locate the affected corner (height sensors are located at each wheel, typically on rear suspension for AWD models)

Procedure

1. 1

   Raise and support vehicle
   Loosen the wheel lug nuts on the affected corner. Raise the vehicle with a floor jack at the manufacturer's designated jacking point near the wheel being serviced. Install jack stands under the frame rail for safety. Remove the wheel completely.
   Torque spec

   Wheel Lug Nuts136 Nm (100 lb-ft)
2. 2

   Access the height sensor
   Locate the height sensor mounted to the lower control arm or suspension knuckle area. The sensor will have a connecting link rod attached to the suspension component. On rear suspension, it is typically mounted to the trailing arm or lower control arm with the link connecting to the knuckle or upper mount.
   ℹ️Sensor location varies by production year. 2016-2020 models typically mount on rear trailing arm, 2021+ may have revised mounting points.
3. 3

   Disconnect electrical connector
   Locate the electrical connector for the height sensor. Press the release tab and carefully pull the connector straight off the sensor. Inspect the connector terminals for corrosion or damage. If connector is corroded, clean with electrical contact cleaner.
   ⚠Do not pull on wires, only on the connector body to prevent wire damage.
4. 4

   Remove sensor link rod
   The sensor has a link rod connecting it to a suspension component. Remove the retaining clip or fastener at the ball joint connection point. This is typically a small E-clip or snap ring. Carefully pry the link rod ball joint from its socket. Note the orientation and position for reinstallation.
   ℹ️Take a photo of the sensor position and link rod angle before removal for reference during installation.
5. 5

   Remove sensor mounting bolts
   Remove the mounting bolts securing the height sensor to its bracket on the suspension component. There are typically 2-3 bolts. If bolts are corroded, apply penetrating oil and allow to soak for several minutes before attempting removal.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
6. 6

   Remove height sensor
   Carefully remove the height sensor from its mounting location. Route the electrical connector and wiring through any clips or brackets. Inspect the mounting bracket for damage or excessive corrosion. Clean the mounting surface with a wire brush if necessary.
   ⚠Note the routing path of the sensor wiring to ensure proper reinstallation without pinch points.
7. 7

   Prepare new sensor
   Remove the new height sensor from packaging. Verify it matches the original sensor design and electrical connector type. Transfer any reusable brackets or hardware if not included with the new sensor. Set the sensor to the approximate same position as the old sensor was installed.
   ℹ️Some replacement sensors come pre-calibrated to a neutral position. Do not manually adjust the sensor arm before installation.
8. 8

   Install new sensor
   Position the new height sensor onto the mounting bracket on the suspension component. Route the wiring harness through the same path as the original, ensuring no contact with moving parts or heat sources. Start all mounting bolts by hand before tightening.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Connect sensor link rod
   Attach the link rod ball joint to its connection point on the suspension. Ensure the ball joint is fully seated in its socket. Install the retaining clip or snap ring to secure the connection. Verify the link rod moves freely through its range of motion without binding.
   ⚠Ensure the link rod is at approximately the same angle as the original installation. Incorrect positioning will cause improper height readings.
10. 10

    Connect electrical connector
    Plug the electrical connector onto the new height sensor. Ensure it clicks into place and the locking tab engages fully. Secure any wiring clips along the harness routing path to prevent wire chafing or damage.
    ℹ️Verify the connector seal is properly seated to prevent water intrusion into the sensor.
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the wheel onto the hub. Thread all lug nuts by hand initially. Raise the vehicle slightly to remove the jack stands. Lower the vehicle until the tire just contacts the ground. Tighten lug nuts in a star pattern to specification. Fully lower the vehicle and perform final torque verification.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify sensor link rod retaining clip is properly installed
3. Check that all wiring is secured and routed away from moving suspension components
4. Confirm no tools or parts were left in the wheel well area

Verification

• Start the vehicle and observe the instrument cluster for any air suspension warning lights or messages
• If available, use a scan tool to check for suspension-related fault codes
• Drive the vehicle slowly and observe suspension response through normal height adjustments
• If suspension does not adjust properly or warning lights remain, sensor calibration using dealer-level scan tool may be required
• Perform a test drive and verify normal suspension operation through various ride height modes if equipped
• Recheck wheel lug nut torque after 50-100 miles of driving

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