This procedure covers removal and replacement of the headlight assembly on a 2016-2024 Hyundai Tucson with 2.5L I4 engine, including proper electrical disconnection and torque specifications.

Warnings

Tools required

Parts

• Headlight assembly (left or right as needed) × 1 — Use OEM specification or certified aftermarket equivalent
• Headlight bulb retaining clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and turn off ignition
2. Allow headlights to cool completely if recently operated
3. Open hood and secure with prop rod
4. Gather all tools and new headlight assembly
5. Verify replacement headlight assembly matches the side being replaced (driver or passenger)

Procedure

1. 1

   Access headlight assembly mounting area
   Locate the headlight assembly from the engine bay. On the 2016-2024 Tucson, the headlight is accessible from above once the hood is open. Identify the electrical connector at the rear of the headlight assembly and the mounting bolts visible from the top.
2. 2

   Disconnect headlight electrical connector
   Locate the main electrical connector at the rear of the headlight assembly. Press the release tab on the connector and pull straight back to disconnect. If multiple connectors are present (for DRL, turn signal, etc.), disconnect all connectors from the headlight assembly. Note the routing of wiring harnesses for reinstallation.
3. 3

   Remove upper headlight assembly mounting bolts
   Using a 10mm socket, remove the headlight assembly bolts visible from the top of the engine bay. Typically there are two to three bolts securing the top of the assembly. Keep these bolts organized as they will be reused during installation.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
4. 4

   Remove lower mounting fastener
   Reach below the headlight assembly or access from the wheel well area to locate the lower mounting fastener. This may be a bolt or a push-pin clip depending on model year. Remove the fastener using appropriate tool (10mm socket or trim tool). On some models, partial removal of the front wheel well liner provides better access.
5. 5

   Release headlight assembly from retaining clips
   With all bolts removed, gently pull the headlight assembly forward from the front of the vehicle. The assembly may be held by alignment pins or clips at the outer edge near the fender. Apply even pressure and wiggle slightly if needed to release the assembly from these retaining features. Do not force; verify all fasteners are removed if resistance is encountered.
6. 6

   Remove headlight assembly from vehicle
   Once freed from all mounting points, carefully withdraw the headlight assembly forward and out of the vehicle. Maneuver around any remaining wiring or obstructions. Set the old assembly aside on a protected surface to avoid scratching the lens.
7. 7

   Transfer components if necessary
   If the replacement headlight assembly does not include bulbs or other components, carefully transfer them from the old assembly. Turn bulb retainers counterclockwise to remove. Handle bulbs only by their base. Inspect all seals and gaskets; replace if damaged or degraded.
8. 8

   Install new headlight assembly
   Position the new headlight assembly, aligning the mounting pins and clips with their corresponding holes in the body. Push the assembly rearward until it seats fully against the body panel and alignment pins engage. Ensure the assembly sits flush with adjacent body panels before fastening.
9. 9

   Install lower mounting fastener
   Secure the lower mounting point first to stabilize the assembly. Install the lower bolt or push-pin clip and hand-tighten. This ensures proper alignment before torquing upper bolts.
10. 10

    Install and torque upper mounting bolts
    Install the upper headlight assembly bolts by hand, ensuring they thread smoothly without cross-threading. Once all bolts are hand-tight, torque each bolt to specification using a torque wrench in a cross-pattern to ensure even pressure distribution.
    Torque spec

    Headlight Assembly Bolts10 Nm (7 lb-ft)
11. 11

    Reconnect electrical connectors
    Reconnect all electrical connectors to the rear of the headlight assembly, ensuring each connector clicks securely into place. Follow the original wiring routing noted during disassembly. Verify all locking tabs are fully engaged.
12. 12

    Test headlight operation
    Turn the ignition to the ON position (engine does not need to start). Test all headlight functions: low beam, high beam, turn signal, and daytime running lights (DRL) if equipped. Verify proper operation before closing hood and completing final verification.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Confirm headlight assembly is flush with surrounding body panels
3. If wheel well liner was disturbed, ensure all clips are properly reinstalled
4. Check that no tools or parts are left in the engine bay

Verification

• Test all headlight functions with ignition on: low beam, high beam, DRL, and turn signals
• Verify headlight beam pattern aims properly and inspect for any light leaks around assembly
• Confirm headlight assembly is securely mounted with no movement or rattles
• Check for proper alignment with adjacent body panels and consistent gap spacing
• Test headlight aim on a wall or garage door at night if available; professional aim adjustment may be required

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