This procedure covers the removal and replacement of the headlight switch assembly on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Headlight switch assembly × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn ignition off and remove key or FOB from vehicle
3. Allow at least 3 minutes after turning off ignition before disconnecting battery to allow airbag system capacitors to discharge
4. Open driver's door and ensure all lights and accessories are off

Procedure

1. 1

   Disconnect battery negative terminal
   Open hood and locate the battery in the engine compartment. Using a 10mm wrench or socket, loosen the negative (-) terminal bolt and remove the cable from the battery post. Secure the cable away from the battery to prevent accidental reconnection.
   Torque spec

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

   Remove lower dash panel
   Locate the lower dash panel beneath the steering column. Using a trim removal tool, carefully pry out the panel starting from the bottom edge. Release the clips by gently pulling the panel away from the dash. Disconnect any electrical connectors for courtesy lights or diagnostic port if attached to the panel. Set panel aside.
3. 3

   Remove driver's side knee bolster
   Identify the knee bolster panel directly above the lower dash panel. Remove the mounting screws (typically 2-3 screws) using a Phillips screwdriver or appropriate socket. Carefully pull the bolster panel away from the dash, releasing any remaining clips. Set aside in a safe location.
4. 4

   Access headlight switch mounting area
   With the knee bolster removed, you now have access to the rear of the dashboard control panel where the headlight switch is mounted. Use a flashlight to illuminate the area and identify the headlight switch connector and mounting mechanism.
5. 5

   Disconnect headlight switch electrical connector
   Locate the electrical connector on the rear of the headlight switch assembly. Press the locking tab on the connector and pull it straight back to disconnect. Note the connector orientation for reassembly. If the connector is difficult to access, you may need to remove additional trim or the entire control panel bezel.
6. 6

   Remove headlight switch mounting fasteners
   Identify the mounting screws or clips securing the headlight switch to the dashboard panel. Remove any screws using the appropriate driver. If the switch uses a twist-lock mechanism, rotate the switch counterclockwise approximately 1/4 turn to release it from the panel.
7. 7

   Remove headlight switch assembly
   Carefully pull the headlight switch assembly straight back and out of the dashboard panel. Take care not to damage the surrounding trim or adjacent controls. Inspect the mounting area for any damage or debris and clean if necessary.
8. 8

   Install new headlight switch
   Position the new headlight switch assembly into the dashboard panel opening. Ensure it is oriented correctly with the connector facing the proper direction. If using a twist-lock design, insert the switch and rotate clockwise 1/4 turn until it locks into place. If using screws, align the switch and hand-start all fasteners before tightening.
9. 9

   Secure switch mounting fasteners
   If applicable, tighten the headlight switch mounting screws evenly. Do not overtighten plastic-mounted screws as this can crack the mounting points. Verify the switch is seated flush with the surrounding panel and operates smoothly through its full range of motion.
10. 10

    Reconnect electrical connector
    Align the electrical connector with the headlight switch terminals and push firmly until you hear or feel the locking tab click into place. Gently tug on the connector to verify it is fully seated and locked.
11. 11

    Reinstall knee bolster and lower dash panel
    Position the knee bolster panel back into place and secure with the original mounting screws. Reinstall the lower dash panel by aligning the clips and pressing firmly until all clips engage. Reconnect any electrical connectors that were disconnected during removal.
12. 12

    Reconnect battery negative terminal
    Place the negative battery cable back onto the negative battery post. Tighten the terminal bolt to the specified torque using a torque wrench. Ensure the connection is tight and secure but do not exceed the specified torque to avoid damaging the battery post.
    ⚠Do not overtighten battery terminal bolts beyond specified torque as this can damage the battery post threads or crack the post.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all trim panels are properly secured and all clips are fully engaged
2. Check that no tools or parts were left in the dashboard area
3. Ensure all electrical connectors are fully seated and locked

Verification

• Turn ignition to ON position without starting engine and verify dash lights illuminate
• Test headlight switch through all positions: off, parking lights, low beams, high beams, and auto (if equipped)
• Verify instrument panel dimmer function operates correctly if integrated with headlight switch
• Start engine and confirm headlights function properly in all modes
• Check that automatic headlight function operates correctly if equipped (turn switch to AUTO and cover ambient light sensor)
• Verify daytime running lights function as designed
• Reset clock and radio presets as needed

More procedures for this vehicle