This procedure covers the removal and replacement of ignition coil packs on the 2016-2024 Hyundai Tucson with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Ignition coil pack × 4 — Use OEM specification
• Spark plugs (if replacing) × 4 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch.
2. Park vehicle on level surface and engage parking brake.
3. Open hood and secure with prop rod.
4. Disconnect negative battery terminal and wait 3 minutes for system capacitors to discharge.

Procedure

1. 1

   Remove engine cover
   Grasp the engine cover firmly at the front corners and pull upward to disengage the rubber grommets from the mounting posts. The cover is not bolted and should release with moderate upward force. Set cover aside.
2. 2

   Locate ignition coils
   Identify the four ignition coils positioned directly on top of the engine valve cover. Each coil is connected to a wiring harness connector and sits atop a spark plug. Note cylinder positions (1-4 from passenger side to driver side when viewed from front of vehicle).
3. 3

   Disconnect coil electrical connectors
   Press down on the locking tab of each coil connector and pull straight up to disconnect. Do not pull on the wiring itself. The connectors may be stiff; wiggle gently while pulling if needed. Disconnect all four coils before proceeding.
4. 4

   Remove ignition coil mounting bolts
   Using a 10mm socket with extension, remove the single bolt securing each ignition coil to the valve cover. Keep bolts organized by cylinder if diagnosing a specific misfire. The bolts are approximately 50mm long.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
5. 5

   Extract ignition coils
   Grasp each coil firmly and pull straight upward with steady pressure. The coil boots create a seal around the spark plugs and may require moderate force to break free. Twist gently while pulling if coil is stuck, but do not bend or rock excessively. Remove all four coils.
6. 6

   Inspect coil boots and spark plug wells
   Examine the rubber boot on each coil for cracks, tears, or oil contamination. Check spark plug wells for oil, coolant, or debris accumulation. If oil is present, valve cover gasket or spark plug tube seals may need replacement. Use compressed air to clean debris from spark plug wells before proceeding.
   ⚠Oil in spark plug wells indicates a valve cover gasket leak that should be addressed to prevent coil failure.
7. 7

   Replace spark plugs (if applicable)
   If replacing spark plugs during this service, use a 16mm spark plug socket to remove old plugs. Apply a thin coat of anti-seize compound to the threads of new spark plugs (avoid getting anti-seize on the electrode). Thread new plugs by hand to avoid cross-threading, then torque to specification using a torque wrench.
   ⚠Over-torquing spark plugs in aluminum heads can strip threads. Use a torque wrench and do not exceed specification.
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
8. 8

   Apply dielectric grease to new coils
   Apply a thin coating of dielectric grease to the inside of each new coil boot. This aids in future removal and prevents moisture intrusion. Do not use excessive grease as it can attract debris.
9. 9

   Install new ignition coils
   Align each coil boot with its corresponding spark plug and push down firmly until the coil seats fully against the valve cover. The boot should compress and the coil mounting hole should align with the threaded hole in the valve cover. You should feel the coil snap into place over the spark plug.
10. 10

    Install and torque coil mounting bolts
    Thread each coil mounting bolt by hand to ensure proper alignment, then torque to specification using a torque wrench. Tighten all four bolts in sequence from cylinder 1 to cylinder 4.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect electrical connectors
    Push each electrical connector onto its corresponding coil until you hear and feel a distinct click. Gently tug on each connector to verify it is fully seated and locked in place.
12. 12

    Reinstall engine cover and reconnect battery
    Align the engine cover grommets with the mounting posts and press down firmly until all grommets are fully seated. Reconnect the negative battery terminal. No tools are required for the engine cover installation.

Reassembly

1. Double-check that all electrical connectors are fully seated and locked.
2. Verify engine cover is properly seated on all mounting posts.
3. Ensure no tools or parts are left in the engine bay.

Verification

• Start the engine and verify smooth idle with no misfires or check engine light.
• Listen for any unusual sounds such as arcing or clicking from the ignition system.
• Rev engine gently to 2000-3000 RPM and confirm smooth operation across all cylinders.
• If a scan tool is available, check for any stored misfire codes after a brief test drive.
• Verify engine cover is secure and not rattling during engine operation.

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