Replace both headlight assemblies on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, including removal of front bumper cover and proper electrical connector handling.

Warnings

Tools required

Parts

• Driver side headlight assembly × 1 — Use OEM specification for 2.5L AWD model year
• Passenger side headlight assembly × 1 — Use OEM specification for 2.5L AWD model year
• Push-in plastic clips (fender liner) × 4 — Replacement for broken clips

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn steering wheel to full left position for easier access to passenger side, full right for driver side
3. Allow engine to cool completely if recently driven
4. Open hood and support securely
5. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge

Procedure

1. 1

   Disconnect battery negative terminal
   Using a 10mm socket, loosen the negative battery terminal bolt. Remove the negative cable from the battery and secure it away from the battery post to prevent accidental reconnection during the repair.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Remove front wheel well liners (partial)
   Turn the steering wheel fully to one side to access the fender liner. Remove the plastic push clips and screws securing the front portion of the wheel well liner to access the headlight assembly from the side. Fold the liner back for access. Repeat for both sides.
3. 3

   Remove upper bumper cover fasteners
   Locate and remove all Phillips screws along the top edge of the front bumper cover where it meets the hood opening. Typically 6-8 screws run across the top. Also remove the two screws at each headlight opening that secure the bumper to the headlight bracket.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Remove lower bumper cover fasteners
   From underneath the vehicle, remove all Phillips screws and plastic push clips securing the lower edge of the bumper cover. Remove approximately 6-8 fasteners along the bottom and the screws in the wheel well area on both sides.
5. 5

   Detach bumper cover from fenders
   At each side of the bumper where it meets the fender, remove the plastic clips or screws securing the bumper to the fender liner and body. Gently pull the bumper cover away from the fender edge on both sides to release any remaining clips.
   ⚠Have a helper support the bumper cover during removal to prevent it from falling and being damaged
6. 6

   Remove front bumper cover
   With all fasteners removed, carefully pull the bumper cover straight forward away from the vehicle. Disconnect any fog light connectors or parking sensor connectors if equipped before fully removing the bumper. Set bumper cover on a protected surface to avoid scratches.
7. 7

   Remove driver side headlight mounting bolts
   Locate the three mounting bolts securing the driver side headlight assembly. Remove all three bolts using a 10mm socket. The bolts are typically located at the top and sides of the headlight bracket.
   ℹ️Note the position and length of each mounting bolt as they may be different lengths
   Torque spec

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

   Disconnect driver side headlight electrical connectors
   Reach behind the driver side headlight assembly and disconnect all electrical connectors. This includes the main headlight bulb connector, high beam connector, turn signal connector, and daytime running light connector. Press the release tabs while pulling the connectors straight out.
9. 9

   Remove driver side headlight assembly
   Carefully pull the driver side headlight assembly straight forward out of the mounting position. Guide the assembly past any wiring harnesses and set aside in a safe location.
10. 10

    Remove passenger side headlight mounting bolts
    Locate the three mounting bolts securing the passenger side headlight assembly. Remove all three bolts using a 10mm socket.
    Torque spec

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

    Disconnect passenger side headlight electrical connectors
    Reach behind the passenger side headlight assembly and disconnect all electrical connectors. Press the release tabs while pulling the connectors straight out. Ensure all connectors are fully disconnected before attempting to remove the assembly.
12. 12

    Remove passenger side headlight assembly
    Carefully pull the passenger side headlight assembly straight forward out of the mounting position and set aside in a safe location.
13. 13

    Install new passenger side headlight assembly
    Position the new passenger side headlight assembly into the mounting location, ensuring proper alignment with the mounting holes and body. Reconnect all electrical connectors by pressing them firmly until they click into place. Install the three mounting bolts hand-tight first, then torque to specification.
    Torque spec

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

    Install new driver side headlight assembly
    Position the new driver side headlight assembly into the mounting location, ensuring proper alignment with the mounting holes and body. Reconnect all electrical connectors by pressing them firmly until they click into place. Install the three mounting bolts hand-tight first, then torque to specification.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
15. 15

    Reinstall front bumper cover
    With assistance, position the front bumper cover back onto the vehicle. Reconnect any fog light or sensor connectors. Align the bumper with the fenders and body panels. Install all mounting screws and clips in reverse order of removal, starting with upper fasteners, then sides, then lower fasteners. Torque cover screws to specification.
    ⚠Ensure proper alignment of bumper cover before tightening fasteners to avoid gaps or misalignment
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
16. 16

    Reinstall wheel well liners and reconnect battery
    Reposition the wheel well liners and secure with all original fasteners and clips. Replace any broken clips with new ones. Clean the battery terminal posts and cable ends. Reconnect the negative battery cable and torque the terminal bolt to specification.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Ensure bumper cover is properly aligned with even gaps around all edges
3. Replace any broken plastic clips or fasteners
4. Check that all mounting bolts are torqued to specification

Verification

• Turn ignition to ON position without starting engine and verify both headlights illuminate (low beam, high beam, and turn signals)
• Start the engine and verify daytime running lights function properly on both sides
• Test all headlight functions including high beams, low beams, turn signals, and parking lights
• Verify headlight aim is correct - adjust if necessary using headlight adjustment screws
• Inspect bumper cover alignment and verify all gaps are even and consistent
• Check for any warning lights on the dashboard related to exterior lighting
• Reset power window auto function if necessary by fully lowering then raising each window and holding the switch up for 2 seconds

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