Replace the HID headlight ballast module that controls the high-intensity discharge bulb operation on the 2016-2024 Hyundai Tucson 2.5L AWD.

Warnings

Tools required

Parts

• HID ballast module × 1 — Use OEM specification - verify left/right designation
• Plastic clips/retainers — If damaged during removal

Preparation

1. Park vehicle on level surface and turn off all lights
2. Allow HID system to cool for at least 10 minutes if recently operated
3. Open hood and secure with prop rod
4. Disconnect negative battery terminal and wait minimum 5 minutes for system discharge
5. Identify which ballast (left or right) requires replacement based on headlight malfunction

Procedure

1. 1

   Remove headlight assembly access cover
   Locate the plastic access cover on the rear of the headlight assembly in the engine bay. Turn the cover counterclockwise or remove retaining clips to expose the HID ballast mounting area. Some models use a dust cover that pulls straight off.
2. 2

   Disconnect HID bulb connector
   Locate the HID bulb connector attached to the ballast output. Press the locking tab and pull the connector straight out from the ballast. Do not twist or bend the connector excessively. Note the orientation of the keyed connector.
   ⚠Do not disconnect connector while ignition is on or recently operated. High voltage may arc.
3. 3

   Disconnect ballast power connector
   Locate the main power connector from the vehicle harness to the ballast input. Press the locking clip and carefully pull the connector free. This connector typically has a 3-4 pin configuration with a secondary locking tab.
4. 4

   Remove ballast ground connection
   Using an 8mm or 10mm socket (model dependent), remove the ground bolt securing the ballast ground wire to the vehicle chassis or mounting bracket. Keep the ground bolt and washer for reinstallation. Inspect the ground contact point and clean if corroded.
   ℹ️A corroded ground connection is a common cause of HID ballast failure. Clean mounting surfaces thoroughly.
   Torque spec

   Ground Bolt14 Nm (10 lb-ft)
5. 5

   Remove ballast mounting bolts
   Locate the ballast mounting bolts securing the module to the headlight assembly or mounting bracket. Using an 8mm socket, remove the two or three mounting bolts. Support the ballast with one hand to prevent it from falling once bolts are removed.
   Torque spec

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

   Remove ballast from vehicle
   Carefully withdraw the ballast module from its mounting location. Some models require sliding the ballast forward or rotating slightly to clear mounting tabs. Inspect the mounting bracket and rubber grommets for damage or wear.
7. 7

   Transfer components to new ballast
   If the new ballast does not include mounting hardware or ground wire, transfer these components from the old ballast. Verify the new ballast part number matches the vehicle application and side (left/right). Check that all connector seals are present and in good condition.
8. 8

   Install new ballast
   Position the new ballast module into the mounting bracket, aligning the mounting holes. Insert mounting bolts finger-tight first to ensure proper alignment. Once all bolts are started, torque the module mounting bolts to specification in a cross-pattern.
   ⚠Ensure ballast is correctly oriented and seated fully before tightening. Misalignment can damage connectors.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Connect ballast ground
   Attach the ground wire to the mounting point on the chassis or bracket. Ensure the mating surfaces are clean and free of paint or corrosion for optimal electrical contact. Install the ground bolt and torque to specification.
   Torque spec

   Ground Bolt14 Nm (10 lb-ft)
10. 10

    Connect electrical connectors
    Connect the main power harness connector to the ballast input, ensuring the locking tab clicks into place. Connect the HID bulb connector to the ballast output, verifying proper seating and alignment. Gently tug each connector to confirm secure connection.
11. 11

    Reconnect battery and test
    Reconnect the negative battery terminal and torque to specification. Turn the headlight switch to the on position and verify the HID bulb ignites and reaches full brightness within 10-15 seconds. Check for any error codes on the instrument cluster.
    ℹ️HID bulbs may flicker or appear dim for the first few seconds during warm-up. This is normal operation.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
12. 12

    Reinstall access cover
    Once operation is verified, reinstall the headlight assembly access cover by aligning the tabs and turning clockwise or pressing retaining clips into place. Ensure the cover is fully seated to prevent moisture intrusion.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Ensure ground connections are tight and contact surfaces are clean
3. Confirm headlight access cover is properly sealed to prevent moisture entry
4. Clear any diagnostic trouble codes that may have been set from the ballast failure

Verification

• Start the vehicle and turn on headlights to verify both low and high beam operation
• Observe that HID bulb reaches full brightness within 15 seconds without flickering or shutting off
• Check instrument cluster for any headlight warning indicators or error messages
• Verify no condensation or moisture is visible in the headlight assembly
• Test headlight function several times (on/off cycles) to ensure consistent ballast operation

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